ENGINE UNIT DISASSEMBLY


  1. REMOVE OIL FILLER CAP SUB-ASSEMBLY


    1. A0041KW

      Remove the oil filler cap sub-assembly.

  2. REMOVE OIL FILLER CAP GASKET


    1. A0043WP

      Remove the oil filler cap gasket.

  3. REMOVE ENGINE COVER JOINT BOLT


    1. A0040AM

      Remove the 3 engine cover joint bolts.

  4. REMOVE WIRING HARNESS CLAMP BRACKET


    1. A0043US

      Remove the bolt and wiring harness clamp bracket.

  5. REMOVE SPARK PLUG


    1. A00443L

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

  6. REMOVE CAMSHAFT POSITION SENSOR


    1. A00436Z

      Remove the bolt and camshaft position sensor.

  7. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY


    1. A00400W

      Remove the bolt and camshaft timing oil control valve assembly.

    2. Remove the O-ring from the camshaft timing oil control valve.

  8. REMOVE CRANKSHAFT POSITION SENSOR


    1. A0041OC

      Remove the bolt and crankshaft position sensor.

  9. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY


    1. A0043G2

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

  10. REMOVE KNOCK SENSOR


    1. A00406Z

      Remove the bolt and knock sensor.

  11. REMOVE ENGINE COOLANT TEMPERATURE SENSOR


    1. A00430J

      Remove the engine coolant temperature sensor and gasket.

  12. 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.

  13. REMOVE CYLINDER HEAD COVER GASKET


    1. A00429K

      Remove the cylinder head cover gasket.

  14. 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.

  15. REMOVE OIL FILTER CAP ASSEMBLY


    1. A00406CE04
      Text in Illustration
      *1 Cap Rib
      *2 Oil Filter Bracket Clip

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

      SST
      09228-06501

      Note

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

      Tech Tips

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

    2. Remove the oil filter cap assembly.

    3. A0043APE01
      Text in Illustration
      *1 Oil Filter Element
      *2 O-ring

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

      Note

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

  16. REMOVE WATER INLET SUB-ASSEMBLY


    1. A00423H

      Remove the bolt, 2 nuts, water inlet sub-assembly and gasket.

  17. REMOVE WATER INLET SUB-ASSEMBLY STUD BOLT


    1. Using an E5 "TORX" socket wrench, remove the 2 water inlet sub-assembly stud bolts.

      Note

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

  18. 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.

  19. 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.

  20. 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.

  21. 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.

  22. 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.

  23. REMOVE CHAIN TENSIONER SLIPPER


    1. A0043NG

      Remove the chain tensioner slipper from the cylinder block.

  24. REMOVE NO. 1 CHAIN VIBRATION DAMPER


    1. A0041EB

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

  25. REMOVE NO. 2 CHAIN VIBRATION DAMPER


    1. A00417J

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

  26. 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.

  27. REMOVE CRANKSHAFT TIMING SPROCKET


    1. A004415

      Remove the crankshaft timing sprocket.

  28. REMOVE NO. 2 CHAIN SUB-ASSEMBLY


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

    2. A0043J8E02

      Using SST, remove the oil pump drive shaft sprocket nut while holding the crankshaft pulley.

      SST
      09213-58014   ( 91551-80840 )
      09330-00021

    3. Remove the crankshaft pulley and crankshaft pulley bolt.

    4. A0042K5

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

    5. A0041ESE01
      Text in Illustration
      *1 Oil Pump Drive Gear
      *2 Oil Pump Drive Shaft Gear
      *3 No. 2 Chain Sub-assembly

      Remove the oil pump drive gear, oil pump drive shaft gear and No. 2 chain sub-assembly.

  29. REMOVE NO. 1 CRANKSHAFT POSITION SENSOR PLATE


    1. A00436C

      Remove the No. 1 crankshaft position sensor plate.

  30. REMOVE CRANKSHAFT TIMING GEAR KEY


    1. A0042RJE02
      Text in Illustration
      *1 Protective Tape

      Using a screwdriver, remove the 2 crankshaft timing gear keys.

      Tech Tips

      Tape the screwdriver tip before use.

  31. 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.

  32. 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.

  33. 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.

  34. 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.

  35. REMOVE CAMSHAFT


    1. A0041R9

      Remove the camshaft.

  36. REMOVE NO. 2 CAMSHAFT


    1. A004479

      Remove the No. 2 camshaft.

  37. REMOVE CAMSHAFT HOUSING STRAIGHT PIN

    Note

    It is not necessary to remove a straight pin unless it is being replaced.

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


    1. A0043SU

      Remove the 16 No. 1 valve rocker arms.

      Tech Tips

      Arrange the removed parts in the correct order.

  39. REMOVE VALVE LASH ADJUSTER ASSEMBLY


    1. A0043MA

      Remove the 16 valve lash adjusters from the cylinder head.

      Tech Tips

      Arrange the removed parts in the correct order.

  40. REMOVE VALVE STEM CAP


    1. A0040ZF

      Remove the 16 valve stem caps.

      Tech Tips

      Arrange the removed parts in the correct order.

  41. REMOVE OIL CONTROL VALVE FILTER


    1. A0042BA

      Remove the oil control valve filter from the No. 1 camshaft bearing cap.

  42. REMOVE NO. 1 CAMSHAFT BEARING


    1. A0040H0

      Remove the 2 No. 1 camshaft bearings.

  43. REMOVE NO. 2 CAMSHAFT BEARING


    1. A0042MN

      Remove the 2 No. 2 camshaft bearings.

  44. 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.

  45. REMOVE CYLINDER HEAD SUB-ASSEMBLY


    1. A0040ZAE01

      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.

  46. REMOVE CYLINDER HEAD GASKET


    1. A0043PE

      Remove the cylinder head gasket.

  47. REMOVE VENTILATION VALVE SUB-ASSEMBLY


    1. A0043BH

      Remove the ventilation valve sub-assembly.

  48. REMOVE OIL PAN DRAIN PLUG


    1. A0040MT

      Remove the oil pan drain plug and gasket.

  49. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY


    1. A0042FK

      Remove the 10 bolts and 2 nuts.

    2. A0041DC

      Insert the blade of an oil pan seal cutter between the crankcase and oil pan. Cut through the sealer and remove the No. 2 oil pan sub-assembly.

      Note

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

  50. REMOVE OIL PUMP ASSEMBLY


    1. A00406O

      Remove the 3 bolts and oil pump assembly.

  51. REMOVE STIFFENING CRANKCASE ASSEMBLY


    1. A0041AT

      Uniformly loosen and remove the 11 bolts.

    2. A00430BE03
      Text in Illustration
      *1 Protective Tape

      Using a screwdriver, remove the stiffening crankcase assembly by prying between the stiffening crankcase assembly and cylinder block.

      Tech Tips

      Tape the screwdriver tip before use.

      Note

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

  52. REMOVE NO. 1 TAPER SCREW PLUG


    1. A003ZYH

      Remove the 2 No. 1 taper screw plugs.

  53. REMOVE STIFFENING CRANKCASE STUD BOLT


    1. Using an E5 "TORX" socket wrench, remove the 2 stiffening crankcase stud bolts.

      Note

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

  54. REMOVE STIFFENING CRANKCASE RING PIN


    1. Remove the 2 stiffening crankcase ring pins.

      Note

      It is not necessary to remove a ring pin unless it is being replaced.

  55. REMOVE REAR ENGINE OIL SEAL


    1. A0041PU

      Remove the rear engine oil seal from the cylinder block.