ENGINE UNIT DISASSEMBLY


  1. REMOVE SPARK PLUG

    A00DUZD

  2. REMOVE OIL FILLER CAP SUB-ASSEMBLY

    A00DRN2

  3. REMOVE OIL FILLER CAP GASKET

    A00DSE3

  4. REMOVE CAMSHAFT POSITION SENSOR


    1. A00DR56

      Remove the bolt and camshaft position sensor.

  5. REMOVE CRANKSHAFT POSITION SENSOR


    1. A00DUC7

      Disconnect the wire harness clamp.

    2. Disconnect the wire harness from the wire harness clamp bracket.

    3. A00DRIO

      Remove the 2 bolts and sensor.

  6. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY


    1. A00DU2J

      Remove the bolt, nut and V-ribbed belt tensioner.

  7. REMOVE VENTILATION VALVE SUB-ASSEMBLY


    1. A00DQRM

      Using a 22 mm deep socket wrench, remove the ventilation valve from the cylinder head cover.

  8. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A00DTZ5E02
      Text in Illustration
      *1 Nut

      Remove the 8 bolts, 2 nuts, cylinder head cover and gasket.

  9. REMOVE CYLINDER HEAD COVER GASKET

    A00DT6K

  10. REMOVE OIL FILTER SUB-ASSEMBLY


    1. A00DUOA

      except Rough Road Area Specification Vehicles:

      Detach the 2 clips and open the engine under cover as shown in the illustration.

    2. A00DRV2E01

      Using SST, remove the oil filter.

      SST
      09228-06501

  11. REMOVE OIL FILTER UNION


    1. A00DTHZ

      Using a 12 mm hexagon wrench, remove the oil filter union.

  12. REMOVE WATER PUMP PULLEY

    A00DQPZE03

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

      SST
      09960-10010   ( 09962-01000, 09963-00700 )

  13. REMOVE WATER PUMP ASSEMBLY

    A00DRKJE01

    1. Disconnect the clamp of the crankshaft position sensor from the water pump.

    2. Disconnect the wire of the crankshaft position sensor from the clamp bracket.

      Text in Illustration
      *1 Bracket
    3. A00DUEIE05
      Text in Illustration
      *1 Bracket

      Remove the 4 bolts, 2 nuts and clamp bracket.

    4. A00DSAAE05

      Using a screwdriver, pry between the water pump and cylinder block, and then remove the water pump.

      Tech Tips

      Tape the screwdriver tip before use.

      Note

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

  14. REMOVE OIL PAN DRAIN PLUG


    1. Remove the drain plug and gasket.

  15. REMOVE OIL PAN SUB-ASSEMBLY


    1. A00DTK4E01

      Remove the 12 bolts and 2 nuts.

    2. A00DSJCE10

      Insert the blade of an oil pan seal cutter between the crankcase, chain cover and oil pan, and cut off the applied sealer and remove the oil pan.

      Note

      Be careful not to damage the contact surface of the crankcase, chain cover and oil pan.

  16. REMOVE CRANKSHAFT PULLEY


    1. A00DUQ8E01

      Using SST, loosen the crankshaft pulley bolt.

      SST
      09213-54015   ( 91651-60855 )
      09330-00021

    2. Further loosen the pulley bolt until 2 or 3 threads are engaged with the crankshaft.

    3. A00DPQ8E01

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

      SST
      09950-50013   ( 09951-05010, 09952-05010, 09953-05020, 09954-05021, 09957-04010 )

      Tech Tips

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

  17. SET NO. 1 CYLINDER TO TDC/COMPRESSION


    1. A00DU0XE03
      Text in Illustration
      *1 Timing Mark
      *2 Groove

      Turn the crankshaft pulley until the groove and the timing mark "0" on the timing chain cover are aligned.

    2. Check that each timing mark on the camshaft timing gear and sprocket is aligned with the timing marks located on the No. 1 and No. 2 bearing caps as shown in the illustration.

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

  18. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY


    1. A00DRL0E01

      Remove the 2 nuts, chain tensioner and gasket.

      Note

      Do not turn the crankshaft without the chain tensioner.

  19. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY


    1. A00DPMA

      Remove the 3 bolts and engine mounting bracket RH.

    2. A00DQSV

      Using an E10 "TORX" socket, remove the stud bolt for the V-ribbed belt tensioner.

    3. A00DQ4KE07
      Text in Illustration
      *1 Nut

      Remove the 12 bolts and 2 nuts.

    4. A00DQSH

      Remove the timing chain cover by prying the areas between the timing chain cover, cylinder head and cylinder block with a screwdriver.

      Tech Tips

      Tape the screwdriver tip before use.

      Note

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

  20. REMOVE TIMING CHAIN COVER OIL SEAL


    1. A00DPT7

      Place the timing chain cover on wooden blocks.

    2. Using a screwdriver, pry 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.

  21. REMOVE NO. 1 CRANKSHAFT POSITION SENSOR PLATE

    A00DQ1U

  22. REMOVE TIMING CHAIN GUIDE


    1. A00DUVEE01

      Remove the bolt and timing chain guide.

  23. REMOVE CHAIN TENSIONER SLIPPER


    1. A00DU98

      Remove the bolt and chain tensioner slipper.

  24. REMOVE NO. 1 CHAIN VIBRATION DAMPER


    1. A00DQM6

      Remove the 2 bolts and chain vibration damper.

  25. REMOVE CHAIN SUB-ASSEMBLY

    A00DRZP

  26. REMOVE CRANKSHAFT TIMING SPROCKET

    A00DRXD

  27. REMOVE NO. 2 CHAIN SUB-ASSEMBLY


    1. A00DT98E02
      Text in Illustration
      *1 Groove

      Turn the crankshaft 90° counterclockwise to align the adjusting hole of the oil pump drive shaft sprocket with the groove of the oil pump.

    2. A00DRE3E02
      Text in Illustration
      *1 Groove

      Insert a 4 mm diameter bar into the adjusting hole of the oil pump drive shaft sprocket to lock the gear in position, and then remove the nut.

    3. A00DUA3E05
      Text in Illustration
      *1 Bolt
      *2 Chain Tensioner Plate
      *3 Spring

      Remove the bolt, chain tensioner plate and spring.

    4. Remove the oil pump drive sprocket, oil pump drive shaft sprocket and No. 2 chain.

  28. REMOVE KEY


    1. A00DTK8

      Remove the 2 keys from the crankshaft.

  29. REMOVE OIL PUMP ASSEMBLY


    1. A00DPY6E01

      Remove the 3 bolts, oil pump and gasket.

  30. REMOVE NO. 2 CAMSHAFT


    1. A00DU1TE01

      Using several steps, uniformly loosen and remove the 10 bearing cap bolts in the sequence shown in the illustration.

      Tech Tips

      Arrange the removed parts in the correct order.

      Note

      Uniformly loosen the bolts while keeping the camshaft level.

    2. Remove the 5 bearing caps.

    3. Remove the No. 2 camshaft.

  31. REMOVE CAMSHAFT


    1. A00DPQTE01

      Using several steps, uniformly loosen and remove the 10 bearing cap bolts in the sequence shown in the illustration.

      Tech Tips

      Arrange the removed parts in the correct order.

      Note

      Uniformly loosen the bolts while keeping the camshaft level.

    2. Remove the 5 bearing caps.

    3. Remove the camshaft.

  32. REMOVE NO. 2 CAMSHAFT BEARING


    1. A00DTJUE02

      Remove the No. 2 camshaft bearing from the cylinder head.

  33. REMOVE NO. 1 CAMSHAFT BEARING


    1. A00DQOT

      Remove the camshaft bearing from the No. 1 camshaft bearing cap.

  34. REMOVE CYLINDER HEAD SUB-ASSEMBLY


    1. A00DUJ4E08

      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. A00DTYH

      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.

  35. REMOVE CYLINDER HEAD GASKET

    A00DSFI

  36. REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY


    1. A00DQBW

      Remove the water drain cock from the stiffening crankcase.

    2. Remove the water drain cock plug from the water drain cock.

  37. REMOVE NO. 3 CYLINDER BLOCK STRAIGHT SCREW PLUG WITH HEAD


    1. A00DUSD

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

  38. REMOVE ENGINE REAR OIL SEAL


    1. A00DQK7E01
      Text in Illustration
      *1 Cut Position

      Using a knife, cut off the lip of the oil seal.

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

      Tech Tips

      Tape the screwdriver tip before use.

      Note

      After removing, check the crankshaft for damage. If damaged, smooth the surface with 400-grit sandpaper.

  39. REMOVE STIFFENING CRANKCASE ASSEMBLY


    1. A00DPUBE03

      Using several steps, uniformly loosen and remove the 11 bolts in the sequence shown in the illustration.

    2. A00DUCH

      Remove the crankcase by prying the areas between the crankcase and cylinder block.

      Note

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

    3. Remove the O-ring from the cylinder block.