CAMSHAFT REMOVAL


  1. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE

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  2. INSTALL ENGINE STAND


    1. Install the engine onto an engine stand with the bolts.

  3. REMOVE ENGINE HANGERS


    1. A0042RK

      Remove the 2 bolts and 2 engine hangers.

  4. REMOVE THROTTLE BODY ASSEMBLY


    1. w/ Stud Bolt:


      1. A0042Y9

        Disconnect the throttle body assembly connector.

      2. Slide the 2 clips and disconnect the 2 water by-pass hoses from the throttle body assembly.

      3. Remove the 2 bolts, 2 nuts and throttle body assembly from the intake manifold.

    2. w/o Stud Bolt:


      1. A0040S6

        Disconnect the throttle body assembly connector.

      2. Slide the 2 clips and disconnect the 2 water by-pass hoses from the throttle body assembly.

      3. Remove the 4 bolts and throttle body assembly from the intake manifold.

    3. A0041CI

      Remove the gasket from the intake manifold.

  5. REMOVE EGR PIPE ASSEMBLY


    1. A0042P5

      Disconnect the 2 wire harness clamps.

    2. A0042LP

      Remove the bolt and wire harness support.

    3. A004131

      Remove the 4 bolts, EGR pipe assembly and 2 gaskets.

  6. REMOVE EGR WITH COOLER PIPE SUB-ASSEMBLY


    1. A0043ZK

      Disconnect the connector, wire harness clamp and 4 water hoses.

    2. A00444ME01
      Text in Illustration
      *1 Stud Bolt and Nut

      Remove the 4 nuts and bolt.

    3. Using an E8 "TORX" socket wrench, remove the 4 stud bolts and EGR valve with cooler assembly.

    4. Remove the gasket.

    5. A0043W3

      Remove the 2 nuts, EGR with cooler pipe sub-assembly and gasket.

  7. REMOVE INTAKE MANIFOLD


    1. A00428G

      Disconnect the 3 connectors and 2 wire harness clamps.

    2. Remove the engine oil level dipstick.

    3. A0041JP

      Disconnect the wire harness clamp, and then remove the 2 bolts and engine oil level dipstick guide sub-assembly.

    4. Remove the O-ring from the engine oil level dipstick guide sub-assembly.

    5. A0043W5

      Disconnect the fuel vapor feed hose.

    6. Slide the clip and disconnect the ventilation hose.

    7. A0043TU

      Remove the 2 bolts, 2 nuts and intake manifold.

    8. Remove the No. 1 intake manifold to head gasket from the intake manifold.

    9. w/ Stud Bolt:


      1. A0043KZ

        Using an E6 "TORX" socket wrench, remove the 2 stud bolts from the intake manifold.

        Tech Tips

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

  8. REMOVE FUEL VAPOR FEED PIPE


    1. A00432P

      Remove the bolt and fuel vapor feed pipe.

  9. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY


    1. A0042QB

      Remove the bolt.

    2. A0043UV

      Remove the 2 bolts and fuel delivery pipe sub-assembly.

      Note

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

  10. REMOVE NO. 1 DELIVERY PIPE SPACER


    1. A0041XV

      Remove the 2 delivery pipe spacers from the cylinder head.

  11. REMOVE FUEL INJECTOR ASSEMBLY


    1. A0040PN

      Pull the 4 fuel injector assemblies out of the fuel delivery pipe sub-assembly.

    2. Remove the O-ring from each fuel injector assembly.

    3. For reinstallation, attach a tag or label to each fuel injector assembly shaft.

      Note

      Prevent entry of foreign matter by covering the fuel injectors with plastic bags.

    4. A0043BG

      Remove the 4 injector vibration insulators.

  12. REMOVE IGNITION COIL ASSEMBLY


    1. A0042QC

      Disconnect the 4 ignition coil connectors.

    2. Remove the 4 bolts and 4 ignition coils.

      Note

      When removing each ignition coil, do not damage the plug cap on the engine head cover opening or the upper edge of the spark plug tube.

  13. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A004075

      Remove the 13 bolts, seal washer and cylinder head cover sub-assembly.

      Note

      As the gaskets may stick to the cylinder head cover, be careful not to drop any of the gaskets into the engine when removing the cylinder head cover.

    2. A0042NG

      Remove the 2 gaskets from the camshaft bearing cap.

  14. REMOVE CYLINDER HEAD COVER GASKET


    1. A00429K

      Remove the cylinder head cover gasket.

  15. REMOVE SPARK PLUG TUBE GASKET


    1. A00430L

      Pry up the claws of the ventilation baffle plate.

      Note

      Do not deform the claws of the ventilation baffle plate more than necessary.

    2. A0041Q2

      Using a screwdriver as shown in the illustration, deform each spark plug tube gasket inwards and remove the 4 spark plug tube gaskets from the cylinder head cover sub-assembly.

      Note


      • As much as possible prevent the spark plug tube gaskets from being deformed. The removed spark plug tube gaskets will be used when reinstalling the new spark plug tube gaskets.

      • Do not damage the cylinder head cover sub-assembly.

      • Make sure not to damage the spark plug tube gasket and cylinder head cover sub-assembly when inserting the screwdriver in the joint area.

      Tech Tips

      If the cylinder head cover sub-assembly is damaged, smooth the surface with 400-grit sandpaper.

  16. SET NO. 1 CYLINDER TO TDC/COMPRESSION


    1. A0042QTE01
      Text in Illustration
      *1 Timing Mark
      *2 Timing Notch
      *3 Timing Mark (Rectangle)
      *4 Mark (Circle)

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

      Tech Tips

      There are 3 marks on the camshaft timing sprocket. Make sure that the timing mark (rectangle) is at the top.

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

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

  17. REMOVE CRANKSHAFT PULLEY


    1. A0042CWE02
      Text in Illustration
      *a Hold
      *b Turn

      Using SST, hold the pulley in place and loosen the pulley bolt.

      SST
      09213-58014   ( 91551-80840 )
      09330-00021
    2. A00413PE02
      Text in Illustration
      *a Hold
      *b Turn

      Using SST, remove the crankshaft pulley and pulley bolt.

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

      Tech Tips

      If necessary, remove the pulley and pulley bolt using SST.

  18. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY


    1. A004278

      Remove the 2 nuts, bracket, No. 1chain tensioner assembly and gasket.

      Note

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

  19. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY


    1. Using a 8mm deep socket wrench, remove the stud bolt from the engine mounting bracket RH.

    2. A00410X

      Remove the 3 bolts and engine mounting bracket RH.

    3. A0040J5

      Remove the 4 bolts and oil filter bracket.

    4. A004078

      Remove the 2 O-rings.

    5. A00401WE01
      Text in Illustration
      *1 Gasket

      Remove the 18 bolts and gasket.

    6. A0040Y1E01
      Text in Illustration
      *1 Protective Tape

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

      Note


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

      • Pry the timing chain cover out evenly in order to prevent damaging the knock pins.

      Tech Tips

      Tape the screwdriver tip before use.

    7. A00447T

      Remove the 3 O-rings.

  20. REMOVE TIMING CHAIN COVER OIL SEAL


    1. Place the timing chain cover sub-assembly on wooden blocks.

    2. A0040P1E01
      Text in Illustration
      *1 Protective Tape
      *2 Wooden Block

      Using a screwdriver and hammer, knock out the timing chain cover oil seal.

      Tech Tips

      Tape the screwdriver tip before use.

      Note

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

  21. REMOVE CHAIN TENSIONER SLIPPER


    1. A0043NG

      Remove the chain tensioner slipper from the cylinder block.

  22. REMOVE NO. 1 CHAIN VIBRATION DAMPER


    1. A0041EB

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

  23. REMOVE NO. 2 CHAIN VIBRATION DAMPER


    1. A00417J

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

  24. REMOVE CHAIN SUB-ASSEMBLY


    1. A0042GL

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

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

      Tech Tips

      Be sure to release the chain sub-assembly from the sprocket completely.

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

  25. INSPECT CAMSHAFT TIMING GEAR ASSEMBLY


    1. Inspect the lock of the camshaft timing gear assembly.

    2. A0042W7E02
      Text in Illustration
      *1 Adhesive Tape
      *a Adhesive Tape Sealing Area
      *b Prick a Hole

      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.

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

    4. A0040DV

      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. A0043BI

      Turn the camshaft timing gear assembly 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.

  26. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY


    1. A0043D9
      Text in Illustration
      *1 Flange Bolt
      *a Do not remove

      Remove the flange bolt while holding the hexagonal portion of the camshaft with a wrench, and then remove the camshaft timing gear assembly.

      Note


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

      • A00433IE04

        Be sure not to remove the other 4 bolts.

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

  27. REMOVE CAMSHAFT TIMING SPROCKET


    1. A004460

      Remove the flange bolt while holding the hexagonal portion of the camshaft with a wrench, and then remove the camshaft timing sprocket.

  28. REMOVE CAMSHAFT BEARING CAP


    1. A0043AEE01

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

    2. A00419UE01

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

      Note

      Uniformly loosen the bearing cap bolts while keeping the camshaft housing level.

    3. Remove the 5 bearing caps.

      Tech Tips

      Arrange the removed parts in the correct order.

  29. REMOVE CAMSHAFT


    1. A0041R9

      Remove the camshaft.

  30. REMOVE NO. 2 CAMSHAFT


    1. A004479

      Remove the No. 2 camshaft.

  31. REMOVE NO. 1 CAMSHAFT BEARING


    1. A0040H0

      Remove the 2 No. 1 camshaft bearings.

  32. REMOVE NO. 2 CAMSHAFT BEARING


    1. A00421D

      Remove the 2 No. 2 camshaft bearings.

  33. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY


    1. A0041WB

      Remove the 2 bolts.

    2. A0042FWE02
      Text in Illustration
      *1 Protective Tape

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

      Note

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

      Tech Tips

      Tape the screwdriver tip before use.