ENGINE UNIT DISASSEMBLY


  1. REMOVE REAR ENGINE OIL SEAL


    1. A01170VE06
      Text in Illustration
      *1 Protective Tape
      *a Cut Position

      Using a knife, cut off the oil seal lip.

    2. Using a screwdriver with its tip wrapped with protective tape, pry out the rear engine oil seal.

  2. REMOVE OIL FILLER CAP SUB-ASSEMBLY

    A0119W0

    1. Remove the oil filler cap.

  3. REMOVE OIL FILLER CAP GASKET


    1. A0118HF

      Remove the gasket from the oil filler cap.

  4. REMOVE SPARK PLUG

    A011A99E01
    Text in Illustration
    *1 14 mm Spark Plug Wrench

    1. Using a 14 mm spark plug wrench, remove the 4 spark plugs.

  5. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY

    A011AB8

    1. Remove the 2 bolts, 2 O-rings and the 2 camshaft timing oil control valves.

  6. REMOVE NO. 1 CRANKSHAFT POSITION SENSOR

    A011A0K

    1. Remove the 2 bolts and the 2 No. 1 crankshaft position sensors.

  7. REMOVE VENTILATION VALVE SUB-ASSEMBLY

    A0117UJ

    1. Remove the ventilation valve.

  8. REMOVE VENTILATION SYSTEM GROMMET

    A0119MR

    1. Remove the ventilation system grommet from the cylinder head cover.

  9. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY

    A011BQBE01
    Text in Illustration
    *1 Seal Washer

    1. Remove the 17 bolts, 2 seal washers and the cylinder head cover.

      Note

      Be careful not to drop any of the gaskets into the engine when removing the cylinder head cover because the gaskets may stick to the cylinder head cover.

    2. A01186E

      Remove the cylinder head cover gasket.

  10. REMOVE CAMSHAFT BEARING CAP OIL HOLE GASKET


    1. A011ASE

      Remove the 2 camshaft bearing cap oil hole gaskets from the camshaft bearing cap.

  11. REMOVE CRANKSHAFT POSITION SENSOR

    A011BVM

    1. Remove the bolt and the crankshaft position sensor.

  12. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY

    A0119XV

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

  13. REMOVE KNOCK SENSOR

    A011893

    1. Remove the bolt and sensor.

  14. REMOVE ENGINE COOLANT TEMPERATURE SENSOR

    A011AA3

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

    2. Remove the gasket from the engine coolant temperature sensor.

  15. REMOVE OIL FILTER ELEMENT


    1. A0119ZDE02
      Text in Illustration
      *1 Pipe
      *2 Hose

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

    2. A011B5Y

      Remove the oil filter drain plug.

    3. A01176PE01
      Text in Illustration
      *1 Cap
      *2 Valve
      *3 Pipe
      *4 O-ring
      *5 Hose

      Install the pipe to the oil filter cap.

      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. A01187N

      Check that oil is drained from the oil filter. Then disconnect the pipe as shown in the illustration.

    5. Remove the O-ring.

    6. A01196ZE01

      Using SST, remove the oil filter cap.

      SST
      09228-06501
    7. A0118MNE03
      Text in Illustration
      *1 O-ring
      *2 Oil Filter Element

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

      Note

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

  16. REMOVE WATER PUMP PULLEY

    A011BEJE01

    1. Using SST, remove the 4 bolts and water pump pulley.

      SST
      09960-10010   ( 09962-01000, 09963-00600 )

  17. SET NO. 1 CYLINDER TO TDC/COMPRESSION

    A0119SVE01
    Text in Illustration
    *1 Timing Mark
    *2 Groove

    1. Turn the crankshaft pulley until its groove and the groove of the timing chain cover are aligned.

    2. Check that each timing mark of the camshaft timing gear and sprocket are located as shown in the illustration. If not, turn the crankshaft 1 revolution (360°) to align the timing marks as shown in the illustration.

  18. REMOVE CRANKSHAFT PULLEY

    A01170JE01

    1. Using SST, remove the crankshaft pulley bolt.

      SST
      09960-10010   ( 09962-01000, 09963-01000 )

    2. Remove the crankshaft pulley from the crankshaft.

  19. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY

    A011A38

    1. Remove the 5 bolts, the water pump and the water pump gasket from the timing chain cover.

    2. A0117GS

      Remove the 3 bolts and the engine mounting bracket.

    3. A011BK7E01
      Text in Illustration
      *1 Seal Washer

      Remove the 21 bolts and seal washer.

    4. A011AS0E01
      Text in Illustration
      *1 Protective Tape

      Using a screwdriver with its tip wrapped with protective tape, remove the timing chain cover by prying between the timing chain cover and cylinder head or cylinder block.

      Note

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

    5. A01194Z

      Remove the 2 O-rings.

    6. A0118R7

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

  20. REMOVE WATER INLET

    A01179B

    1. Remove the 3 bolts and the water inlet.

  21. REMOVE NO. 2 WATER INLET HOUSING GASKET

    A0118P6

    1. Remove the No. 2 water inlet housing gasket from the water inlet.

  22. REMOVE TIMING CHAIN COVER OIL SEAL


    1. A01195KE03
      Text in Illustration
      *1 Protective Tape
      *2 Wooden Block

      Using a screwdriver with its tip wrapped with protective tape, remove the timing chain cover oil seal.

      Note

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

  23. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY

    A0117MZE01

    1. Set the camshaft timing gear, camshaft timing exhaust gear and crankshaft in the positions (20° ATDC) shown in the illustration.

      Text in Illustration
      *1 Timing Mark
      *a TDC
    2. A0119YJE03
      Text in Illustration
      *1 Stopper Plate
      *2 Plunger
      A0117XZ Push

      Push down on the stopper plate to release the lock and push in the plunger.

    3. A011B2ZE02
      Text in Illustration
      *1 Stopper Plate

      Pull up the stopper plate with the plunger pushed to the end and lock the plunger.

    4. A01188UE02
      Text in Illustration
      *1 Bar

      Insert a 3 mm (0.118 in.) diameter bar into the hole in the stopper plate and lock the plunger.

    5. A01189X

      Remove the 2 nuts and the No. 1 chain tensioner.

    6. A01187M

      Remove the gasket from the cylinder head.

  24. REMOVE NO. 2 CHAIN VIBRATION DAMPER

    A011A28

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

  25. REMOVE TIMING CHAIN TENSION ARM

    A011BU1

    1. Remove the bolt and the timing chain tension arm.

  26. REMOVE CHAIN SUB-ASSEMBLY


    1. Remove the chain.

  27. REMOVE TIMING CHAIN GUIDE

    A011741

    1. Remove the 2 bolts and the timing chain guide.

  28. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY

    A011BCLE03

    1. Check the lock of the camshaft timing gear.

    2. Release the lock pin.

      Note

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


      1. 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.

        Note

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

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

      3. A0119VI
        Text in Illustration
        *1 Prick a Hole
        *2 Adhesive Tape
        *a Adhesive Tape Sealing Area

        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 adhesive tape.

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

        • Do not lock the camshaft timing gear. If it is locked, release the lock pin again.

        Tech Tips


        • The camshaft timing gear may be turned in the advance direction without applying any force.

        • If enough air pressure cannot be applied because of air leakage from the port, releasing the lock pin may be difficult.

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

    3. A01192QE03
      Text in Illustration
      *a Do Not Remove

      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.

  29. REMOVE CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY

    A011BEME02
    Text in Illustration
    *a Do Not Remove

    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.

  30. REMOVE CAMSHAFT BEARING CAP

    A011BCJE01

    1. Uniformly loosen and remove the 5 bearing cap bolts in the sequence shown in the illustration.

    2. A01176CE01

      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.

  31. REMOVE NO. 2 CAMSHAFT

    A0118XE

    1. Remove the No. 2 camshaft.

  32. REMOVE CAMSHAFT

    A011709

    1. Remove the camshaft.

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

    A0118J2

    1. Remove the 16 valve rocker arms.

      Tech Tips

      Arrange the removed parts in the correct order.

  34. REMOVE VALVE LASH ADJUSTER ASSEMBLY

    A011AFY

    1. Remove the 16 valve lash adjusters from the cylinder head.

      Tech Tips

      Arrange the removed parts in the correct order.

  35. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY


    1. A0117DH

      Remove the 3 bolts.

    2. A011A0EE02
      Text in Illustration
      *1 Protective Tape

      Using a screwdriver with its tip wrapped with protective tape, remove the camshaft housing by prying between the cylinder head and camshaft housing.

      Note

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

  36. REMOVE CYLINDER HEAD SUB-ASSEMBLY

    A01197AE01

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

      Note

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

    2. Using a screwdriver with its tip wrapped with protective 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.

  37. REMOVE CYLINDER HEAD GASKET

    A0117O6

    1. Remove the cylinder head gasket.

  38. REMOVE CYLINDER BLOCK WATER JACKET SPACER

    A011BSG

    1. Remove the cylinder block water jacket spacer from the cylinder block.

  39. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY

    A0118H1

    1. Remove the oil pan drain plug and gasket from the No. 2 oil pan.

    2. Remove the 9 bolts.

    3. A01184YE01
      Text in Illustration
      *1 Oil Pan Seal Cutter

      Insert the blade of the oil pan seal cutter between the oil pans as shown in the diagram. Cut through the applied sealer and remove the No. 2 oil pan.

      Note

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

  40. REMOVE OIL PAN SUB-ASSEMBLY

    A0117IN

    1. Uniformly loosen and remove the 10 bolts.

    2. A011AM0E01
      Text in Illustration
      *1 Protective Tape

      Using a screwdriver with its tip wrapped with protective tape, remove the oil pan by prying between the oil pan and cylinder block.

      Note

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

    3. A0119SA

      Remove the gasket from the cylinder block.

  41. REMOVE NO. 1 OIL PAN BAFFLE PLATE

    A011BAC

    1. Remove the 6 bolts and the No. 1 oil pan baffle plate from the oil pan.

  42. REMOVE OIL STRAINER SUB-ASSEMBLY


    1. A0117J7

      Remove the 2 bolts and the oil strainer from the oil pan.