ENGINE UNIT DISASSEMBLY

REMOVE SPARK PLUG

1. 

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

REMOVE OIL FILTER CAP ASSEMBLY

1. 

   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.

   Table 1. Text in Illustration

   *1	Cap Rib
   *2	Oil Filter Bracket Clip

   09228-06501

   Note:

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

   Tip:

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

2. Remove the oil filter cap assembly.

3. 

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

   Table 2. Text in Illustration

   *1	Oil Filter Element
   *2	O-ring

   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.

SET NO. 1 CYLINDER TO TDC/COMPRESSION

1. 

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

   Table 3. Text in Illustration

   *1	Timing Mark
   *2	Timing Notch
   *3	Timing Mark (Rectangle)
   *4	Mark (Circle)

   Tip:

   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.

REMOVE CRANKSHAFT PULLEY

1. 

   Using SST, hold the pulley in place and loosen the pulley bolt.

   Table 4. Text in Illustration

   *a	Hold
   *b	Turn

   09213-58014	91551-80840
   09330-00021

2. 

   Using SST, remove the crankshaft pulley and pulley bolt.

   Table 5. Text in Illustration

   *a	Hold
   *b	Turn

   09950-50013

   09951-05010

   09952-05010

   09953-05020

   09954-05021

REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY

1. 

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

   Note:

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

REMOVE TIMING CHAIN COVER SUB-ASSEMBLY

1. 

   Remove the 3 bolts and engine mounting bracket RH.

2. 

   Remove the 4 bolts and oil filter bracket.

3. 

   Remove the 2 O-rings.

4. 

   Remove the 18 bolts and seal washer.

   Table 6. Text in Illustration

   *1	Seal Washer

5. 

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

   Table 7. Text in Illustration

   *1	Protective Tape

   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.

   Tip:

   Tape the screwdriver tip before use.

6. 

   Remove the 3 O-rings.

REMOVE TIMING CHAIN COVER OIL SEAL

1. Place the timing chain cover on wooden blocks.

2. 

   Using a screwdriver and hammer, knock out the oil seal.

   Table 8. Text in Illustration

   *1	Protective Tape
   *2	Wooden Block

   Tip:

   Tape the screwdriver tip before use.

   Note:

   Do not damage the surface of the oil seal press fit hole.

REMOVE CHAIN TENSIONER SLIPPER

1. 

   Remove the chain tensioner slipper from the cylinder block.

REMOVE NO. 1 CHAIN VIBRATION DAMPER

1. 

   Remove the 2 bolts and chain vibration damper.

REMOVE NO. 2 CHAIN VIBRATION DAMPER

1. 

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

REMOVE CHAIN SUB-ASSEMBLY

1. 

   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.

   Tip:

   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.

REMOVE CRANKSHAFT TIMING SPROCKET

1. 

   Remove the crankshaft timing sprocket.

REMOVE NO. 2 CHAIN SUB-ASSEMBLY

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

2. 

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

   09213-58014	91551-80840
   09330-00021

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

4. 

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

5. 

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

   Table 9. Text in Illustration

   *1	Oil Pump Drive Gear
   *2	Oil Pump Drive Shaft Gear
   *3	No. 2 Chain Sub-assembly

INSPECT CAMSHAFT TIMING GEAR ASSEMBLY

1. 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.

   Table 11. Text in Illustration

   *1	Adhesive Tape
   *a	Adhesive Tape Sealing Area
   *b	Prick a Hole

   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. 

   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).

   Tip:

   Depending on the air pressure applied, the camshaft timing gear may turn in the advance direction without assistance.

6. 

   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.

REMOVE CAMSHAFT TIMING GEAR ASSEMBLY

1. 

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

   Table 12. Text in Illustration

   *1	Flange Bolt
   *a	Do not remove

   Note:
   

   • 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.

REMOVE CAMSHAFT TIMING SPROCKET

1. 

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

   Table 13. Text in Illustration

   *1	Flange Bolt
   *a	Do not remove

   Note:
   

   • 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.

REMOVE CAMSHAFT BEARING CAP

1. 

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

2. 

   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.

   Tip:

   Arrange the removed parts in the correct order.

REMOVE CAMSHAFT

1. 

   Remove the camshaft.

REMOVE NO. 2 CAMSHAFT

1. 

   Remove the No. 2 camshaft.

REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY

1. 

   Remove the 2 bolts.

2. 

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

   Table 14. Text in Illustration

   *1	Protective Tape

   Note:

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

   Tip:

   Tape the screwdriver tip before use.

REMOVE CYLINDER HEAD SUB-ASSEMBLY

1. 

   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.

REMOVE CYLINDER HEAD GASKET

1. 

   Remove the cylinder head gasket.

REMOVE NO. 2 OIL PAN SUB-ASSEMBLY

1. 

   Remove the 10 bolts and 2 nuts.

2. 

   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.

REMOVE OIL PUMP ASSEMBLY

1. 

   Remove the 3 bolts and oil pump.