БЛОК ДВИГАТЕЛЯ РАЗБОРКА

REMOVE SPARK PLUG

1. Using a 14 mm spark plug wrench and 100 mm extension bar, remove the 4 spark plugs.

   

REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY

1. Отсоедините разъем контактного датчика давления масла.

   

2. С помощью удлиненной торцевой головки на 22 мм снимите контактный датчик давления масла.

REMOVE OIL FILTER CAP ASSEMBLY

1. Using SST, loosen the oil filter cap 4 revolutions, align the cap ribs vertically, and drain the remaining engine oil in the oil filter cap.

   

   SST

   09228-06501

   Text in Illustration

   *1	Cap Rib
   *2	Oil Filter Bracket Clip

   Tech Tips

   Set a container below the oil filter cap before loosening the oil filter cap.

   Note

   Do not remove the oil filter bracket clip when removing the oil filter cap assembly.

2. Remove the oil filter cap.

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

   

   Text in Illustration

   *1	Oil Filter Element
   *2	O-Ring

   Note

   Be sure to remove the O-ring (for the cap) by hand, without using any tools, to prevent damage to the groove for the O-ring on the cap.

SET NO. 1 CYLINDER TO TDC/COMPRESSION

1. Turn the crankshaft pulley until its notch and timing mark "0" of the timing chain cover are aligned.

   

   Text in Illustration

   *1	Timing Mark
   *2	Timing Notch

2. Check that timing marks on both the camshaft timing exhaust gear and camshaft timing gear are facing upward as shown in the illustration.

   Tech Tips

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

REMOVE CRANKSHAFT PULLEY

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

   

   Text in Illustration

   *1	Hold
   *2	Turn

   SST

   09213-58014   ( 91551-80840 )

   09330-00021

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

   

   Text in Illustration

   *1	Hold
   *2	Turn

   SST

   09950-50013   ( 09951-05010, 09952-05010, 09953-05020, 09954-05021 )

   Tech Tips

   Apply lubricant to the threads and end of SST.

REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY

1. Remove the 2 nuts, bracket, chain tensioner and gasket.

   

   Note

   Do not turn the crankshaft without the No. 1 chain tensioner installed.

REMOVE TIMING CHAIN COVER SUB-ASSEMBLY

1. Remove the 3 bolts and engine mounting bracket.

   

2. Remove the 4 bolts and oil filter bracket.

   

3. Remove the 2 O-rings.

   

4. Remove the 19 bolts.

   

5. 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.

   

   Text in Illustration

   *1	Protective Tape

   Tech Tips

   Tape the screwdriver tip before use.

   Note

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

6. Remove the 3 O-rings.

   

7. Remove the 3 bolts and water pump.

   

8. Remove the gasket.

   

REMOVE TIMING CHAIN COVER OIL SEAL

1. Place the timing chain cover on wooden blocks.

   

   Text in Illustration

   *1	Wooden Block
   *2	Protective Tape

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

   Tech Tips

   Tape the screwdriver tip before use.

   Note

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

REMOVE CHAIN TENSIONER SLIPPER

1. Remove the chain tensioner slipper.

   

REMOVE NO. 1 CHAIN VIBRATION DAMPER

1. Remove the 2 bolts and chain vibration damper.

   

REMOVE CHAIN SUB-ASSEMBLY

1. Hold the hexagonal portion of the camshaft with a wrench and turn the camshaft timing gear counterclockwise to loosen the chain between the camshaft timing gears.

   

2. With the chain loosened, release the chain from the camshaft timing gear and place it on the camshaft timing gear.

   Tech Tips

   Be sure to release the chain from the sprocket completely.

3. Turn the camshaft clockwise to return it to the original position and remove the chain.

REMOVE NO. 2 CHAIN VIBRATION DAMPER

1. Remove the 2 bolts and chain vibration damper.

   

REMOVE CRANKSHAFT TIMING SPROCKET

1. Remove the crankshaft timing sprocket.

   

REMOVE NO. 2 CHAIN SUB-ASSEMBLY

1. Temporarily install the crankshaft pulley and crankshaft pulley bolt.

   

2. Using SST, hold the crankshaft. Then remove the drive shaft gear nut.

   SST

   09330-00021

   09213-58014   ( 91551-80840 )

3. Remove SST, the crankshaft pulley bolt and crankshaft pulley.

4. Remove the bolt, chain tensioner plate and spring.

   

5. Remove the oil pump drive gear, oil pump drive shaft gear and No. 2 chain.

   

   Text in Illustration

   *1	Oil Pump Drive Gear
   *2	Oil Pump Drive Shaft Gear
   *3	No. 2 Chain Sub-Assembly

INSPECT CAMSHAFT TIMING GEAR ASSEMBLY

1. Inspect the lock of the camshaft timing gear.

   

2. After cleaning and degreasing the VVT oil hole on the intake side of the No. 1 camshaft bearing cap, completely seal the oil hole with adhesive tape or equivalent as shown in the illustration to prevent air from leaking.

   Text in Illustration

   *1	Adhesive Tape Sealing Area
   *2	Prick a Hole
   *3	Adhesive Tape

   Note

   Be sure to cover the oil hole completely because air leaks due to insufficient sealing will prevent the lock pin from being released.

3. Prick a hole in the tape covering the oil hole as shown in the illustration. (Procedure A)

4. Apply approximately 150 kPa (1.5 kgf/cm², 22 psi) of air pressure to the hole pricked in procedure A to release the lock pin.

   

   Note

   • If air leaks out, reattach the adhesive tape.

   • Cover the oil hole with a piece of cloth when applying air pressure to prevent oil from spraying.

5. Forcibly turn the camshaft timing gear in the advance direction (counterclockwise).

   Tech Tips

   Depending on the air pressure applied, the camshaft timing gear may turn in the advance direction without assistance.

6. Turn the camshaft timing gear within its movable range (26.5 to 28.5°) 2 or 3 times without turning it to the most retarded position. Make sure that the camshaft timing gear turns smoothly.

   

7. Remove the adhesive tape from the No. 1 camshaft bearing cap.

INSPECT CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY

1. Check the lock of the camshaft timing exhaust gear.

   

2. After cleaning and degreasing the VVT oil hole on the exhaust side of the No. 1 camshaft bearing cap, completely seal the oil hole with adhesive tape or equivalent as shown in the illustration to prevent air from leaking.

   Text in Illustration

   *1	Adhesive Tape Sealing Area
   *2	Prick a Hole
   *3	Adhesive Tape

   Note

   Be sure to cover the oil hole completely because air leaks due to insufficient sealing will prevent the lock pin from being released.

3. Prick a hole in the tape covering the oil hole as shown in the illustration. (Procedure A)

4. Apply approximately 200 kPa (2.0 kgf/cm², 28 psi) of air pressure to the hole pricked in procedure A to release the lock pin.

   

   Note

   • If air leaks out, reattach the adhesive tape.

   • Cover the oil hole with a piece of cloth when applying air pressure to prevent oil from spraying.

5. Using a screwdriver with its tip wrapped with tape, forcibly turn the camshaft timing exhaust gear in the retard direction (clockwise).

   Note

   • Be sure to keep the camshaft timing exhaust gear in the retard direction using a screwdriver. If the gear is released, it will return to the most advanced position automatically due to the force from the spring.

   • Do not damage the camshaft timing exhaust gear.

6. Using a screwdriver with its tip wrapped with tape, turn the camshaft timing exhaust gear within its movable range (19 to 21°) 2 or 3 times without turning it to the most advanced position. Make sure that the camshaft timing exhaust gear turns smoothly.

   

7. Remove the adhesive tape from the No. 1 camshaft bearing cap.

REMOVE CAMSHAFT TIMING GEAR ASSEMBLY

1. Remove the flange bolt while holding the hexagonal portion of the camshaft, and then remove the camshaft timing gear.

   

   Note

   • Before removing the camshaft timing gear, make sure that the lock pin has been released.

     

   • Be sure not to remove the other 4 bolts.

   • Keep the camshaft timing gear horizontal while removing it from the camshaft.

REMOVE CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY

1. Remove the flange bolt while holding the hexagonal portion of the camshaft, and then remove the camshaft timing exhaust gear.

   

   Note

   • Be sure not to remove the other 4 bolts.

     

   • Keep the camshaft timing exhaust gear horizontal while removing it from the camshaft.

REMOVE CAMSHAFT BEARING CAP

1. Uniformly loosen and remove the 10 bearing cap bolts in the sequence shown in the illustration.

   

2. Uniformly loosen and remove the 15 bearing cap bolts in the sequence shown in the illustration.

   

   Note

   Uniformly loosen the bolts while keeping the camshaft level.

3. Remove the 5 bearing caps.

   Tech Tips

   Arrange the removed parts in the correct order.

REMOVE CAMSHAFT

REMOVE NO. 2 CAMSHAFT

REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY

1. Remove the 2 bolts.

   

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

   

   Text in Illustration

   *1	Protective Tape

   Tech Tips

   Tape the screwdriver tip before use.

   Note

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

REMOVE CYLINDER HEAD SUB-ASSEMBLY

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

   

   Note

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

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

2. Using a screwdriver with its tip wrapped with tape, pry between the cylinder head and cylinder block, and remove the cylinder head.

   Note

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

REMOVE CYLINDER HEAD GASKET

1. Remove the cylinder head gasket.

   

REMOVE VENTILATION VALVE SUB-ASSEMBLY

1. С помощью ключа для контргайки шарового шарнира на 22 мм снимите сапун в сборе.

   

REMOVE NO. 2 OIL PAN SUB-ASSEMBLY

1. Remove the 10 bolts and 2 nuts.

   

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

   

   Note

   • Be careful not to damage the surface of the oil pan which contacts the stiffening crankcase.

   • Be careful not to damage the stiffening crankcase flange.

REMOVE OIL PUMP ASSEMBLY

1. Remove the 3 bolts and oil pump.