ENGINE UNIT DISASSEMBLY

REMOVE SPARK PLUG

1. 

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

REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY

1. Camshaft timing oil control valve assembly (for exhaust side)

   
   
   1. 

      Disconnect the oil control valve connector.

   2. Remove the bolt and oil control valve.

   3. 

      Remove the O-ring from the oil control valve.

      Table 1. Text in Illustration

      *1

      O-ring

2. Camshaft timing oil control valve assembly (for intake side)

   
   
   1. 

      Disconnect the oil control valve connector.

   2. Remove the bolt and oil control valve.

   3. 

      Remove the O-ring from the oil control valve.

      Table 2. Text in Illustration

      *1

      O-ring

REMOVE CAMSHAFT POSITION SENSOR

1. Camshaft position sensor (for exhaust side)

   
   
   1. 

      Disconnect the sensor connector.

   2. Remove the bolt and sensor.

2. Camshaft position sensor (for intake side)

   
   
   1. 

      Disconnect the sensor connector.

   2. Remove the bolt and sensor.

REMOVE VENTILATION VALVE SUB-ASSEMBLY

1. 

   Disconnect the No. 2 ventilation hose from the ventilation valve.

2. 

   Using a 19 mm deep socket wrench, remove the ventilation valve.

   Table 3. Text in Illustration

   *1	19 mm Deep Socket Wrench

REMOVE WATER INLET

1. 

   Remove the 2 nuts and water inlet.

REMOVE THERMOSTAT

1. Remove the thermostat.

2. Remove the gasket from the thermostat.

REMOVE ENGINE WATER PUMP ASSEMBLY

1. 

   Remove the 7 bolts, engine water pump and water pump gasket.

REMOVE OIL COOLER ASSEMBLY

1. 

   Remove the nut, union bolt, seal washer and oil cooler.

   Table 4. Text in Illustration

   *1	Union Bolt
   *2	Seal Washer

2. Remove the 3 gaskets from the oil cooler.

REMOVE ENGINE MOUNTING BRACKET RH

1. 

   Remove the 5 bolts and engine mounting bracket RH.

REMOVE TIMING CHAIN COVER SUB-ASSEMBLY

1. 

   Remove the 17 bolts and 2 nuts.

2. 

   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.

   Note:

   Be careful not to damage the contact surfaces of the cylinder head, camshaft housing, cylinder block, stiffening crankcase and chain cover.

   Tip:

   Tape the screwdriver tip before use.

3. 

   Remove the 3 gaskets from the stiffening crankcase.

REMOVE TIMING CHAIN COVER OIL SEAL

1. 

   Using a screwdriver, pry out the oil seal.

   Tip:

   Tape the screwdriver tip before use.

   Note:

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

SET NO. 1 CYLINDER TO TDC/COMPRESSION

1. 

   Temporarily install the crankshaft pulley bolt.

   Table 7. Text in Illustration

   *1	Timing Mark	*2	Key
   *a	Approximately 7°	*b	Approximately 32°

   Tip:

   "A" is not a timing mark.

2. Rotate the crankshaft clockwise so that the timing marks on the crankshaft timing gear and camshaft timing gears are as shown in the illustration.

   Tip:

   If the timing marks do not align, rotate the crankshaft clockwise again and align the timing marks.

3. Remove the crankshaft pulley bolt.

REMOVE TIMING CHAIN GUIDE

1. 

   Remove the bolt and timing chain guide.

REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY

1. 

   Allow the plunger to extend slightly, and then rotate the stopper plate counterclockwise to release the lock. Once the lock is released, push the plunger into the tensioner.

   Table 8. Text in Illustration

   *1	Stopper Plate
   *2	Plunger

2. 

   Move the stopper plate clockwise to set the lock, and insert a pin into the stopper plate hole.

   Table 9. Text in Illustration

   *1

   Pin

3. 

   Remove the 2 bolts, chain tensioner and gasket.

REMOVE CHAIN TENSIONER SLIPPER

1. 

   Remove the bolt and chain tensioner slipper.

REMOVE NO. 1 CHAIN VIBRATION DAMPER

1. 

   Remove the 2 bolts and No.1 chain vibration damper.

REMOVE CAMSHAFT TIMING GEAR ASSEMBLY

1. 

   Hold the hexagonal portion of the camshaft with a wrench and remove the bolt and camshaft timing gear.

   Note:
   

   • Be careful not to damage the cylinder head or spark plug tube with the wrench.

   • Do not disassemble the camshaft timing gear.

REMOVE CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY

1. 

   Hold the hexagonal portion of the camshaft with a wrench and remove the bolt and camshaft timing exhaust gear.

   Note:
   

   • Be careful not to damage the cylinder head or spark plug tube with the wrench.

   • Do not disassemble the camshaft timing exhaust gear.

REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY

1. 

   Uniformly loosen and remove the 20 bearing cap bolts in the sequence shown in the illustration.

2. 

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

   Tip:

   Tape the screwdriver tip before use.

   Note:

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

REMOVE CAMSHAFT BEARING CAP

1. 

   Remove the 11 bearing cap bolts in the sequence shown in the illustration.

2. Remove the 5 bearing caps.

   Tip:

   Arrange the removed parts in the correct order.

REMOVE CAMSHAFT

1. Remove the No. 1 and No. 2 camshafts.

REMOVE NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY

1. Remove the 16 valve rocker arms from the cylinder head.

   Tip:

   Arrange the removed parts in the correct order.

REMOVE VALVE LASH ADJUSTER ASSEMBLY

1. Remove the 16 valve lash adjusters from the cylinder head.

   Tip:

   Arrange the removed parts in the correct order.

REMOVE VALVE STEM CAP

1. Remove the 16 valve stem caps from the cylinder head.

   Tip:

   Arrange the removed parts in the correct order.

REMOVE CYLINDER HEAD SUB-ASSEMBLY

1. 

   Using a 10 mm bi-hexagon wrench, uniformly loosen the 10 bolts in the sequence shown in the illustration. Remove the 10 cylinder head bolts and plate washers.

   Tip:

   Be sure to keep the removed parts separate for each installation position.

   Note:
   

   • Be careful not to drop washers into the cylinder head.

   • Head warpage or cracking could result from removing bolts in the incorrect order.

2. Remove the cylinder head.

REMOVE CYLINDER HEAD GASKET

1. Remove the cylinder head gasket from the cylinder block.

INSPECT BALANCE SHAFT THRUST CLEARANCE

1. 

   Using a dial indicator, measure the thrust clearance while moving the No. 1 balance shaft back and forth.

   Table 14. Text in Illustration

   *1	No. 1 Balance Shaft

   Standard thrust clearance
   0.05 to 0.09 mm (0.00197 to 0.00354 in.)

   Maximum thrust clearance
   0.09 mm (0.00354 in.)

   If the thrust clearance is more than the maximum, replace the engine balancer assembly.

2. 

   Using a dial indicator, measure the thrust clearance while moving the No. 2 balance shaft back and forth.

   Table 15. Text in Illustration

   *1	No. 2 Balance Shaft

   Standard thrust clearance
   0.05 to 0.09 mm (0.00197 to 0.00354 in.)

   Maximum thrust clearance
   0.09 mm (0.00354 in.)

   If the thrust clearance is more than the maximum, replace the engine balancer assembly.