ENGINE UNIT DISASSEMBLY


  1. REMOVE OIL FILLER CAP SUB-ASSEMBLY


    1. A00DUSK

      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. A005VJW

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

  5. REMOVE CAMSHAFT POSITION SENSOR


    1. A00DQ97

      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. A00DPL5

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

    2. A00DQK5

      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. A00DT9X

      Remove the cylinder head cover gasket.

  13. REMOVE SPARK PLUG TUBE GASKET


    1. A00DSYB

      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 Rib
      *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 assembly.

    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. A00DTPCE01
      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. A00DPUO

      Remove the 19 bolts.

    5. A00DUFAE01
      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. A00DROX

      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. A00DQN3E01

      Remove the chain tensioner slipper.

  25. REMOVE NO. 1 CHAIN VIBRATION DAMPER


    1. A00DSDU

      Remove the 2 bolts and chain vibration damper.

  26. REMOVE CHAIN SUB-ASSEMBLY


    1. A00DS1QE01

      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 NO. 2 CHAIN VIBRATION DAMPER


    1. A00DTKS

      Remove the 2 bolts and chain vibration damper.

  28. REMOVE CRANKSHAFT TIMING SPROCKET


    1. A00DSSN

      Remove the crankshaft timing sprocket.

  29. 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.

  30. REMOVE NO. 1 CRANKSHAFT POSITION SENSOR PLATE


    1. A00DSQH

      Remove the crankshaft position sensor plate.

  31. 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.

  32. INSPECT CAMSHAFT TIMING GEAR ASSEMBLY


    1. A00DPU6E01

      Inspect the lock of the camshaft timing gear.

    2. 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.

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

      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. A00DS9H

      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. A00DU7N

      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.

  33. INSPECT CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY


    1. A00DTV4E01

      Check the lock of the camshaft timing exhaust gear.

    2. 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.

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

      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. A00DR17

      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. A00DSVK

      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.

  34. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY


    1. A00DUC3

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

      Note


      • A00DQXKE02

        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.

  35. REMOVE CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY


    1. A00DT2S

      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.

  36. REMOVE CAMSHAFT BEARING CAP


    1. A00DQAPE01

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

    2. A00DSQXE01

      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.

  37. REMOVE CAMSHAFT

    A00DSUBE01

  38. REMOVE NO. 2 CAMSHAFT

    A00DSD7E01

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


    1. A00DT5QE02

      Remove the 16 valve rocker arms.

      Tech Tips

      Arrange the removed parts in the correct order.

  40. REMOVE VALVE LASH ADJUSTER ASSEMBLY


    1. A00DQYFE02

      Remove the 16 valve lash adjusters from the cylinder head.

      Tech Tips

      Arrange the removed parts in the correct order.

  41. REMOVE OIL CONTROL VALVE FILTER


    1. A00DSW0

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

  42. REMOVE NO. 1 CAMSHAFT BEARING


    1. A00DUA7

      Remove the 2 camshaft bearings.

  43. REMOVE NO. 2 CAMSHAFT BEARING


    1. A00DRFU

      Remove the 2 camshaft bearings.

  44. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY


    1. A00DR9O

      Remove the 2 bolts.

    2. A00DURGE01
      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.

  45. REMOVE VALVE STEM CAP


    1. A00DS86

      Remove the 16 valve stem caps.

      Tech Tips

      Arrange the removed parts in the correct order.

  46. REMOVE CAMSHAFT HOUSING STRAIGHT PIN

    Note

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

  47. 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.

  48. REMOVE CYLINDER HEAD GASKET


    1. A00DTFD

      Remove the cylinder head gasket.

  49. REMOVE VENTILATION VALVE SUB-ASSEMBLY


    1. A00519C

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

  50. REMOVE OIL PAN DRAIN PLUG


    1. A00DTL8

      Remove the drain plug and gasket.

  51. 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.

  52. REMOVE OIL PUMP ASSEMBLY


    1. A00DRCE

      Remove the 3 bolts and oil pump.

  53. 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.

  54. REMOVE NO. 1 TAPER SCREW PLUG


    1. A00DUI4

      Remove the 2 No. 1 taper screw plugs.

  55. REMOVE STIFFENING CRANKCASE STUD BOLT

    Note

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

  56. REMOVE STIFFENING CRANKCASE RING PIN

    Note

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

  57. REMOVE ENGINE REAR OIL SEAL


    1. A00DUP5

      Remove the engine rear oil seal from the cylinder block.