ENGINE UNIT DISASSEMBLY


  1. REMOVE OIL FILLER CAP SUB-ASSEMBLY


    1. A00DRBM

      Remove the oil filler cap.

  2. REMOVE OIL FILLER CAP GASKET


    1. A00DSE3

      Remove the oil filler cap gasket.

  3. REMOVE ENGINE COVER JOINT


    1. A00DU0E

      Remove the 2 engine cover joints.

  4. REMOVE SPARK PLUG


    1. A005RUK

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

  5. REMOVE CAMSHAFT POSITION SENSOR


    1. A00DSDV

      Remove the 2 bolts and 2 camshaft position sensors.

  6. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY


    1. A00DTPN

      Remove the 2 bolts, wire harness bracket and 2 camshaft timing oil control valves.

    2. Remove the 2 O-rings from the camshaft timing oil control valves.

  7. REMOVE CRANKSHAFT POSITION SENSOR


    1. A00DT8B

      Remove the bolt and crankshaft position sensor.

  8. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY


    1. A005SJB

      Disconnect the oil pressure switch connector.

    2. Using a 22 mm deep socket wrench, remove the oil pressure switch.

  9. REMOVE KNOCK SENSOR


    1. A00DQHC

      Remove the bolt and knock sensor.

  10. REMOVE ENGINE COOLANT TEMPERATURE SENSOR


    1. A00DU0BE01

      Using SST, remove the engine coolant temperature sensor and gasket.

      SST
      09817-33190

  11. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A00DQSC

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

    2. A00DSLL

      Remove the 3 gaskets from the camshaft bearing cap.

      Note

      As 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.

  12. REMOVE CYLINDER HEAD COVER GASKET


    1. A00DQEY

      Remove the cylinder head cover gasket.

  13. REMOVE SPARK PLUG TUBE GASKET


    1. A00DPMM

      Pry up the 4 claws of the ventilation baffle plate.

      Note

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

    2. Remove the 4 gaskets from the cylinder head cover.

      Tech Tips

      Prevent the plug tube gaskets from being deformed as much as possible. The removed gaskets will be used when installing new gaskets.

      Note

      Be careful not to damage the cylinder head cover.

  14. REMOVE OIL FILTER CAP ASSEMBLY


    1. A00DU0YE01
      Text in Illustration
      *1 Cap Rid
      *2 Oil Filter Bracket Clip

      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

      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.

    2. Remove the oil filter cap.

    3. A00DSFLE01
      Text in Illustration
      *1 Oil Filter Element
      *2 O-Ring

      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 for the O-ring on the cap.

  15. SET NO. 1 CYLINDER TO TDC/COMPRESSION


    1. A00DSWGE01
      Text in Illustration
      *1 Timing Mark
      *2 Timing Notch

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

    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.

  16. REMOVE CRANKSHAFT PULLEY


    1. A00DT7GE01
      Text in Illustration
      *1 Hold
      *2 Turn

      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.

      SST
      09213-58014   ( 91551-80840 )
      09330-00021
    2. A00DV11E01
      Text in Illustration
      *1 Hold
      *2 Turn

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

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

      Tech Tips

      Apply lubricant to the threads and end of SST.

  17. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY


    1. A00DUPB

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

      Note

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

  18. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY


    1. A00DRLH

      Remove the 3 bolts and engine mounting bracket.

    2. A00DUZI

      Remove the 4 bolts and oil filter bracket.

    3. A00DPKQ

      Remove the 2 O-rings.

    4. A00DQ33

      Remove the 19 bolts.

    5. A00DT2YE02
      Text in Illustration
      *1 Protective Tape

      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.

      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. A00DQMC

      Remove the 3 O-rings.

    7. A00DQKR

      Remove the 3 bolts and water pump.

    8. A00DU13E03

      Remove the gasket.

  19. REMOVE TIMING CHAIN COVER OIL SEAL


    1. A00DT5CE05
      Text in Illustration
      *1 Wooden Block
      *2 Protective Tape

      Place the timing chain cover on wooden blocks.

    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.

  20. REMOVE ENGINE MOUNTING BRACKET STUD BOLT

    Note

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

  21. REMOVE WATER INLET HOUSING STUD BOLT

    Note

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

  22. REMOVE WATER INLET HOUSING


    1. A00DS4N

      Remove the 3 bolts, water inlet housing and gasket.

  23. REMOVE NO. 1 GENERATOR BRACKET


    1. A00DSK8

      Remove the 4 bolts and generator bracket.

  24. REMOVE CHAIN TENSIONER SLIPPER


    1. A00DS61

      Remove the chain tensioner slipper from the cylinder block.

  25. REMOVE NO. 1 CHAIN VIBRATION DAMPER


    1. A00DPP5

      Remove the 2 bolts and chain vibration damper.

  26. REMOVE CHAIN SUB-ASSEMBLY


    1. A00DRAO

      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.

  27. REMOVE CRANKSHAFT TIMING SPROCKET


    1. A00DSSN

      Remove the crankshaft timing sprocket.

  28. REMOVE NO. 2 CHAIN SUB-ASSEMBLY


    1. A00DRCSE01

      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. A00DRMW

      Remove the bolt, chain tensioner plate and spring.

    5. A00DUOTE01
      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.

  29. REMOVE NO. 1 CRANKSHAFT POSITION SENSOR PLATE


    1. A00DSQH

      Remove the crankshaft position sensor plate.

  30. REMOVE CRANKSHAFT TIMING GEAR KEY


    1. A00DTN6E02
      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.

    2. A00DTGPE01
      Text in Illustration
      *1 Adhesive Tape Sealing Area
      *2 Prick a Hole
      *3 Adhesive Tape

      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. A00DQLB

      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. A00DT1O

      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.

  32. INSPECT CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY


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

    2. A00DRUFE01
      Text in Illustration
      *1 Adhesive Tape Sealing Area
      *2 Prick a Hole
      *3 Adhesive Tape

      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.

      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. A00DRHY

      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. A00DTRA

      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.

  33. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY


    1. A00DSZU

      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.

      • A00DQXKE02

        Be sure not to remove the other 4 bolts.

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

  34. REMOVE CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY


    1. A00DUTB

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

      Note


      • A00DTMBE06

        Be sure not to remove the other 4 bolts.

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

  35. REMOVE VALVE ROCKER ARM LOST MOTION DAMPER SUB-ASSEMBLY


    1. A00DQ7GE01
      Text in Illustration
      *1 Shim

      Remove the 2 bolts and valve rocker arm lost motion damper.

      Note


      • Make sure the camshaft housing is installed to the cylinder head when removing or installing a valve rocker arm lost motion damper.

      • If a valve rocker arm lost motion damper is removed, do not remove the camshaft housing.

      • Do not remove the shims. If a shim is removed, replace the camshaft housing as engine malfunctions may result from irregular valve timing.

  36. INSTALL VALVE ROCKER ARM LOST MOTION DAMPER SUB-ASSEMBLY


    1. A00DPOTE01
      Text in Illustration
      *1 Hole for Engine Oil

      Install the valve rocker arm lost motion damper with the 2 bolts. Uniformly tighten the bolts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

    2. Add engine oil into the hole for engine oil.

  37. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY

    Note


    • The camshaft housing is replaced with an assembled unit that includes the camshaft housing, camshafts, camshaft bearing caps, valve rocker shaft and valve rocker arm lost motion damper. Do not disassemble the camshaft housing. If disassembled, replace the camshaft housing sub-assembly.

    • The camshafts cannot be replaced by themselves.

      A00DUY5E01

    1. A00DPOWE01

      Uniformly loosen and remove the 17 bearing cap bolts in the sequence shown in the illustration.

      Note

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

    2. A00DTSFE01
      Text in Illustration
      *1 Protective Tape

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

      Tech Tips

      Tape the screwdriver tip before use.

      Note

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

  38. REMOVE CONTINUOUSLY VARIABLE VALVE LIFT CONTROLLER ASSEMBLY


    1. A00DRP1

      Using a screwdriver, slide the control actuator clip from the control actuator connector.

      Note

      Slide only the upper part of the control actuator clip, as the straight pin may fall if the control actuator clip is completely removed.

    2. A00DR2P

      Remove the bolt.

    3. A00DRRQ

      Using a screwdriver, lightly pry the control actuator connector to make a space between the continuously variable valve lift controller and camshaft housing.

      Note


      • Do not forcefully pry the control actuator connector.

      • Do not damage the camshaft housing or camshaft bearing cap.

    4. A00DPR2

      Using a magnet hand, remove the straight pin from the control actuator connector.

      Tech Tips

      The straight pin can be removed by utilizing the space between the continuously variable valve lift controller and camshaft housing to move the continuously variable valve lift controller so that there is no load on the straight pin.

    5. A00DPUTE01
      Text in Illustration
      *1 Continuously Variable Valve Lift Controller Assembly
      *2 Valve Lift Control Actuator Connector
      *3 O-Ring

      Remove the continuously variable valve lift controller from the camshaft housing.

    6. Remove the O-ring from the continuously variable valve lift controller.

      Note

      The O-ring may remain on the camshaft housing side. Be sure to always remove it.

    7. Rotate the control actuator connector and remove it from the valve rocker shaft.

  39. REMOVE CAMSHAFT HOUSING STUD BOLT

    Note

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

  40. REMOVE CAMSHAFT HOUSING STRAIGHT PIN

    Note

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

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


    1. A00DU00

      Remove the 16 valve rocker arms.

      Tech Tips

      Arrange the removed parts in the correct order.

  42. REMOVE VALVE LASH ADJUSTER ASSEMBLY


    1. A00DSFFE01

      Remove the 16 valve lash adjusters from the cylinder head.

      Tech Tips

      Arrange the removed parts in the correct order.

  43. REMOVE VALVE STEM CAP


    1. A00DS86

      Remove the 16 valve stem caps.

      Tech Tips

      Arrange the removed parts in the correct order.

  44. REMOVE CYLINDER HEAD SUB-ASSEMBLY


    1. A00DUDJE01

      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.

  45. REMOVE CYLINDER HEAD GASKET


    1. A00DTFD

      Remove the cylinder head gasket.

  46. REMOVE VENTILATION VALVE SUB-ASSEMBLY


    1. A00519C

      Using a 22 mm ball joint lock nut wrench, remove the ventilation valve sub-assembly.

  47. REMOVE OIL PAN DRAIN PLUG


    1. A00DTL8

      Remove the drain plug and gasket.

  48. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY


    1. A00DRAC

      Remove the 10 bolts and 2 nuts.

    2. A00DQSJ

      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.

  49. REMOVE OIL PUMP ASSEMBLY


    1. A00DUXT

      Remove the 3 bolts and oil pump.

  50. REMOVE STIFFENING CRANKCASE ASSEMBLY


    1. A00DSXX

      Uniformly loosen and remove the 11 bolts.

    2. A00DTWLE02
      Text in Illustration
      *1 Protective Tape

      Using a screwdriver, remove the stiffening crankcase by prying between the stiffening crankcase 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.

  51. REMOVE NO. 1 TAPER SCREW PLUG


    1. A00DUI4

      Remove the 2 No. 1 taper screw plugs.

  52. REMOVE STIFFENING CRANKCASE STUD BOLT

    Note

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

  53. REMOVE STIFFENING CRANKCASE RING PIN

    Note

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

  54. REMOVE ENGINE REAR OIL SEAL


    1. A00DUP5

      Remove the engine rear oil seal from the cylinder block.