ENGINE UNIT DISASSEMBLY


  1. REMOVE OIL FILLER CAP SUB-ASSEMBLY


    1. A003XDW

      Remove the oil filler cap.

  2. REMOVE OIL FILLER CAP GASKET


    1. A003WE4

      Remove the oil filler cap gasket.

  3. REMOVE ENGINE COVER JOINT BOLT


    1. A003YBY

      Remove the 3 engine cover joint bolts.

  4. REMOVE WIRING HARNESS CLAMP BRACKET


    1. A003XSJ

      Remove the bolt and wiring harness clamp bracket.

  5. REMOVE SPARK PLUG


    1. A003ZL2

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

  6. REMOVE CAMSHAFT POSITION SENSOR


    1. A003VZ2

      Remove the bolt and camshaft position sensor.

  7. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY


    1. A003X5Y

      Remove the bolt and camshaft timing oil control valve.

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

  8. REMOVE CRANKSHAFT POSITION SENSOR


    1. A003ZVS

      Remove the bolt and crankshaft position sensor.

  9. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY


    1. A003WY3

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

  10. REMOVE KNOCK SENSOR


    1. A003YZG

      Remove the bolt and knock sensor.

  11. REMOVE ENGINE COOLANT TEMPERATURE SENSOR


    1. A003YTM

      Remove the engine coolant temperature sensor and gasket.

  12. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A003VEM

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

      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. A003XE0

      Remove the 2 gaskets from the camshaft bearing cap.

  13. REMOVE CYLINDER HEAD COVER GASKET


    1. A003V1Q

      Remove the cylinder head cover gasket.

  14. REMOVE SPARK PLUG TUBE GASKET


    1. A003Y52

      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.

  15. REMOVE OIL FILTER CAP ASSEMBLY


    1. A003XZ3E04
      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

      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.

    2. Remove the oil filter cap assembly.

    3. A003XJAE01
      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.

  16. REMOVE INLET WATER SUB-ASSEMBLY


    1. A003ZEU

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

  17. REMOVE INLET WATER SUB-ASSEMBLY STUD BOLT

    Note

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

  18. SET NO. 1 CYLINDER TO TDC/COMPRESSION


    1. A003W15E01
      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. A003VJEE02
      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. A003VCUE02
      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 )

  20. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY


    1. A003YAP

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

      Note

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

  21. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY


    1. A003WBY

      Remove the 3 bolts and engine mounting bracket RH.

    2. A003W66

      Remove the 4 bolts and oil filter bracket.

    3. A003V4O

      Remove the 2 O-rings.

    4. A003Y3KE01
      Text in Illustration
      *1 Seal Washer

      Remove the 18 bolts and seal washer.

    5. A003VM6E01
      Text in Illustration
      *1 Protective Tape

      Remove the timing chain cover by prying between the timing chain cover 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.

    6. A003XNX

      Remove the 3 O-rings.

  22. REMOVE TIMING CHAIN COVER OIL SEAL


    1. Place the timing chain cover on wooden blocks.

    2. A003YXEE01
      Text in Illustration
      *1 Protective Tape
      *2 Wooden Block

      Using a screwdriver and hammer, knock 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.

  23. REMOVE CHAIN TENSIONER SLIPPER


    1. A003Z3Q

      Remove the chain tensioner slipper from the cylinder block.

  24. REMOVE NO. 1 CHAIN VIBRATION DAMPER


    1. A003WFM

      Remove the 2 bolts and chain vibration damper.

  25. REMOVE NO. 2 CHAIN VIBRATION DAMPER


    1. A003Y2U

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

  26. REMOVE CHAIN SUB-ASSEMBLY


    1. A003WCW

      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. A003XH9

      Remove the crankshaft timing sprocket.

  28. REMOVE NO. 2 CHAIN SUB-ASSEMBLY


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

    2. A003YZ8E02

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

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

    3. Remove SST, the crankshaft pulley and crankshaft pulley bolt.

    4. A003ZM9

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

    5. A003VLZE01
      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. A003V61

      Remove the crankshaft position sensor plate.

  30. REMOVE CRANKSHAFT TIMING GEAR KEY


    1. A003ZOPE02
      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. A003VAFE02
      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. A003YZA

      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. A003ZVZ

      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. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY


    1. A003VJ4
      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.

      Note


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

      • A003W2TE04

        Be sure not to remove the other 4 bolts.

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

  33. REMOVE CAMSHAFT TIMING SPROCKET


    1. A003VJ4
      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.

      Note


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

      • A003W2TE04

        Be sure not to remove the other 4 bolts.

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

  34. REMOVE CAMSHAFT BEARING CAP


    1. A003YDLE01

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

    2. A003XNZE01

      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. A003ZLS

      Remove the camshaft.

  36. REMOVE NO. 2 CAMSHAFT


    1. A003VQU

      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. A003YZQ

      Remove the 16 valve rocker arms.

      Tech Tips

      Arrange the removed parts in the correct order.

  39. REMOVE VALVE LASH ADJUSTER ASSEMBLY


    1. A003WB5

      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. A003WD9

      Remove the 16 valve stem caps.

      Tech Tips

      Arrange the removed parts in the correct order.

  41. REMOVE OIL CONTROL VALVE FILTER


    1. A003WDW

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

  42. REMOVE NO. 1 CAMSHAFT BEARING


    1. A003W9X

      Remove the 2 camshaft bearings.

  43. REMOVE NO. 2 CAMSHAFT BEARING


    1. A003Z37

      Remove the 2 camshaft bearings.

  44. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY


    1. A003YKX

      Remove the 2 bolts.

    2. A003XFLE02
      Text in Illustration
      *1 Protective Tape

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

      Note

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

      Tech Tips

      Tape the screwdriver tip before use.

  45. REMOVE CYLINDER HEAD SUB-ASSEMBLY


    1. A003XVFE01

      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. A003ZMM

      Remove the cylinder head gasket.

  47. REMOVE VENTILATION VALVE SUB-ASSEMBLY


    1. A003YYA

      Remove the ventilation valve sub-assembly.

  48. REMOVE OIL PAN DRAIN PLUG


    1. A003Z4J

      Remove the drain plug and gasket.

  49. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY


    1. A003WMY

      Remove the 10 bolts and 2 nuts.

    2. A003ZNM

      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 contact surfaces of the crankcase, chain cover and oil pan.

  50. REMOVE OIL PUMP ASSEMBLY


    1. A003YQL

      Remove the 3 bolts and oil pump.

  51. REMOVE STIFFENING CRANKCASE ASSEMBLY


    1. A003YN8

      Uniformly loosen and remove the 11 bolts.

    2. A003ZR2E03
      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.

  52. REMOVE NO. 1 TAPER SCREW PLUG


    1. A003XAY

      Remove the 2 No. 1 taper screw plugs.

  53. REMOVE STIFFENING CRANKCASE STUD BOLT

    Note

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

  54. REMOVE STIFFENING CRANKCASE RING PIN

    Note

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

  55. REMOVE ENGINE REAR OIL SEAL


    1. A003V6Q

      Remove the engine rear oil seal from the cylinder block.