ENGINE UNIT DISASSEMBLY

REMOVE SPARK PLUG

1. Using a spark plug wrench, remove the 4 spark plugs.

   

REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY

1. Camshaft timing oil control valve assembly (for exhaust side)

   1. Disconnect the oil control valve connector.

      

   2. Remove the bolt and oil control valve.

   3. Remove the O-ring from the oil control valve.

      

      Text in Illustration

      *1

      O-ring

2. Camshaft timing oil control valve assembly (for intake side)

   1. Disconnect the oil control valve connector.

      

   2. Remove the bolt and oil control valve.

   3. Remove the O-ring from the oil control valve.

      

      Text in Illustration

      *1

      O-ring

REMOVE CAMSHAFT POSITION SENSOR

1. Camshaft position sensor (for Exhaust Side)

   1. Disconnect the sensor connector.

      

   2. Remove the bolt and sensor.

2. Camshaft position sensor (for Intake Side)

   1. Disconnect the sensor connector.

      

   2. Remove the bolt and sensor.

REMOVE CRANKSHAFT POSITION SENSOR

1. Disconnect the sensor connector.

2. Remove the bolt and sensor.

REMOVE VENTILATION VALVE SUB-ASSEMBLY

1. Disconnect the No. 2 ventilation hose from the ventilation valve sub-assembly.

   

2. Using a 19 mm deep socket wrench, remove the ventilation valve sub-assembly.

   

   Text in Illustration

   *1	19 mm Deep Socket Wrench

REMOVE WATER INLET

1. Remove the 2 nuts and water inlet.

   

REMOVE THERMOSTAT

1. Remove the thermostat.

2. Remove the gasket from the thermostat.

REMOVE ENGINE WATER PUMP ASSEMBLY

1. Remove the 7 bolts, engine water pump and gasket.

   

REMOVE ENGINE MOUNTING BRACKET RH

1. Remove the 5 bolts and engine mounting bracket RH.

   

REMOVE TIMING CHAIN COVER SUB-ASSEMBLY

1. Remove the 17 bolts and 2 nuts.

   

2. Remove the timing chain cover by prying between the timing chain cover and cylinder head, camshaft housing, cylinder block and stiffening crankcase with a screwdriver as shown in the illustration.

   

   Note

   Be careful not to damage the contact surfaces of the cylinder head, camshaft housing, cylinder block, stiffening crankcase or chain cover.

   Tech Tips

   Tape the screwdriver tip before use.

3. Remove the 3 gaskets from the stiffening crankcase.

   

REMOVE TIMING CHAIN COVER OIL SEAL

1. Using a screwdriver and wooden block, pry out the oil seal.

   

   Text in Illustration

   *1	Wooden Block

   Note

   Do not damage the surface of the oil seal press fit hole.

   Tech Tips

   Tape the screwdriver tip before use.

SET NO. 1 CYLINDER TO TDC/COMPRESSION

1. Temporarily install the crankshaft pulley bolt.

   

   Text in Illustration

   *a	Approximately 7°	*b	Approximately 32°
   *c	Timing Mark	*d	Key

   Tech Tips

   "A" is not a timing mark.

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.

REMOVE TIMING CHAIN GUIDE

1. Remove the bolt and timing chain guide.

   

REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY

1. Allow the plunger to extend slightly, and then rotate the stopper plate counterclockwise to release the lock. Once the lock is released, push the plunger into the tensioner.

   

   Text in Illustration

   *1	Stopper Plate
   *2	Plunger

2. Move the stopper plate clockwise to set the lock, and insert a pin into the stopper plate hole.

   

   Text in Illustration

   *1

   Pin

3. Remove the 2 bolts, chain tensioner and gasket.

   

REMOVE CHAIN TENSIONER SLIPPER

1. Remove the bolt and chain tensioner slipper.

   

REMOVE NO. 1 CHAIN VIBRATION DAMPER

1. Remove the 2 bolts and chain vibration damper.

   

REMOVE CAMSHAFT TIMING GEAR ASSEMBLY

1. Hold the hexagonal portion of the camshaft with a wrench and remove the bolt and camshaft timing gear assembly.

   

   Text in Illustration

   *a	Hold
   *b	Turn

   Note

   • Be careful not to damage the cylinder head sub-assembly or spark plug tube with the wrench.

   • Do not disassemble the camshaft timing gear assembly.

REMOVE CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY

1. Hold the hexagonal portion of the camshaft with a wrench and remove the bolt and camshaft timing exhaust gear assembly.

   

   Text in Illustration

   *a	Hold
   *b	Turn

   Note

   • Be careful not to damage the cylinder head sub-assembly or spark plug tube with the wrench.

   • Do not disassemble the camshaft timing exhaust gear assembly.

REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY

1. Uniformly loosen and remove the 20 bearing cap bolts in the sequence shown in the illustration.

   

2. Remove the camshaft housing by prying between the cylinder head sub-assembly and camshaft housing sub-assembly with a screwdriver.

   

   Tech Tips

   Tape the screwdriver tip before use.

   Note

   Be careful not to damage the contact surfaces of the cylinder head and camshaft housing sub-assembly.

REMOVE CAMSHAFT BEARING CAP

1. Remove the 11 bearing cap bolts in the sequence shown in the illustration.

   

2. Remove the 5 bearing caps.

   Tech Tips

   Arrange the removed parts in the correct order.

REMOVE CAMSHAFT

1. Remove the camshaft and No. 2 camshaft.

REMOVE NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY

1. Remove the 16 valve rocker arms from the cylinder head sub-assembly.

   Tech Tips

   Arrange the removed parts in the correct order.

REMOVE VALVE LASH ADJUSTER ASSEMBLY

1. Remove the 16 valve lash adjusters from the cylinder head sub-assembly.

   Tech Tips

   Arrange the removed parts in the correct order.

REMOVE VALVE STEM CAP

1. Remove the 16 valve stem caps from the cylinder head sub-assembly.

   Tech Tips

   Arrange the removed parts in the correct order.

REMOVE CYLINDER HEAD SUB-ASSEMBLY

1. Using a 10 mm bi-hexagon wrench, uniformly loosen the 10 bolts in the sequence shown in the illustration. Remove the 10 cylinder head bolts and plate washers.

   

   Tech Tips

   Be sure to keep the removed parts separate for each installation position.

   Note

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

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

2. Remove the cylinder head sub-assembly.

REMOVE CYLINDER HEAD GASKET

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

REMOVE OIL FILTER CAP ASSEMBLY

1. Connect a hose with an inside diameter of 15 mm (0.591 in.) to the pipe.

   

   Text in Illustration

   *1	Pipe
   *2	Hose

2. Remove the oil filter drain plug from the oil filter cap.

   

3. Install the pipe to the oil filter cap.

   

   Text in Illustration

   *1	Valve
   *2	Cap
   *3	O-ring
   *4	Pipe

   Note

   If the O-ring is removed with the drain plug, install the O-ring together with the pipe.

   Tech Tips

   Use a container to catch the draining oil.

4. Check that the oil is drained from the oil filter. Then disconnect the pipe as shown in the illustration and remove the O-ring.

   

5. Using SST, remove the oil filter cap.

   

   Text in Illustration

   *1	Oil Filter Bracket Clip

   SST

   09228-06501

   Note

   Do not remove the oil filter bracket clip.

6. Remove the oil filter element and O-ring from the oil filter cap.

   

   Text in Illustration

   *1	Oil Filter Element
   *2	Oil Filter Cap
   *3	O-ring

   Note

   Be sure to remove the O-ring by hand, without using any tools, to prevent damage to the O-ring groove.

INSPECT BALANCE SHAFT THRUST CLEARANCE

1. Using a dial indicator, measure the thrust clearance while moving the No. 1 balance shaft back and forth.

   

   Standard thrust clearance
   0.05 to 0.09 mm (0.00197 to 0.00354 in.)

   Maximum thrust clearance
   0.09 mm (0.00354 in.)

   If the thrust clearance is more than the maximum, replace the engine balancer assembly.