ENGINE UNIT DISASSEMBLY


  1. REMOVE OIL FILLER CAP SUB-ASSEMBLY


    1. A01IUSZ

      Remove the oil filler cap.

  2. REMOVE OIL FILLER CAP GASKET


    1. A01IPKL

      Remove the oil filler cap gasket.

  3. REMOVE ENGINE COVER JOINT


    1. A01INDE

      Remove the 2 engine cover joints.

  4. REMOVE SPARK PLUG


    1. A01IP08

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

  5. REMOVE CAMSHAFT POSITION SENSOR


    1. A01IUS4

      Remove the 2 bolts and 2 camshaft position sensors.

  6. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY


    1. A01IR9F

      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. A01INT7

      Remove the bolt and crankshaft position sensor.

  8. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY


    1. A01IR6E

      Disconnect the oil pressure switch connector.

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

  9. REMOVE KNOCK SENSOR


    1. A01IU80

      Remove the bolt and knock sensor.

  10. REMOVE ENGINE COOLANT TEMPERATURE SENSOR


    1. A01ITFBE01

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

      SST
      09817-33190

  11. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A01IUMW

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

    2. A01IP7C

      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. A01IU5J

      Remove the cylinder head cover gasket.

  13. REMOVE SPARK PLUG TUBE GASKET


    1. A01IO7K

      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. A01IO0RE01
      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. A01ITMIE01
      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. A01IPJZE01
      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. A01IUGJE01
      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.

      for 86 mm (3.39 in.) Bolt Pitch Type:

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

      for 64 mm (2.52 in.) Bolt Pitch Type:

      SST
      09213-54015
      09330-00021

      Tech Tips

      For the 64 mm (2.52 in.) bolt pitch type, the part number of the installation bolt for SST (crankshaft pulley holding tool) is 91551-00850 (quantity: 2).

    2. A01IQIIE01
      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. A01IUNG

      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. A01IU7T

      Remove the 3 bolts and engine mounting bracket.

    2. A01IPTE

      Remove the 4 bolts and oil filter bracket.

    3. A01ISTB

      Remove the 2 O-rings.

    4. A01IQCN

      Remove the 19 bolts.

    5. A01IO3QE02
      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. A01IO6Z

      Remove the 3 O-rings.

    7. A01IORK

      Remove the 3 bolts and water pump.

    8. A01IOBZE03

      Remove the gasket.

  19. REMOVE TIMING CHAIN COVER OIL SEAL


    1. A01INFPE05
      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. A01ISL3

      Remove the 3 bolts, water inlet housing and gasket.

  23. REMOVE NO. 1 GENERATOR BRACKET


    1. A01IRDB

      Remove the 4 bolts and generator bracket.

  24. REMOVE CHAIN TENSIONER SLIPPER


    1. A01IP0L

      Remove the chain tensioner slipper from the cylinder block.

  25. REMOVE NO. 1 CHAIN VIBRATION DAMPER


    1. A01IMZ9

      Remove the 2 bolts and chain vibration damper.

  26. REMOVE CHAIN SUB-ASSEMBLY


    1. A01IN26

      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. A01IOWH

      Remove the crankshaft timing sprocket.

  28. REMOVE NO. 2 CHAIN SUB-ASSEMBLY


    1. A01INTIE01

      Temporarily install the crankshaft pulley and crankshaft pulley bolt.

    2. Using SST, hold the crankshaft. Then remove the drive shaft gear nut.

      for 86 mm (3.39 in.) Bolt Pitch Type:

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

      for 64 mm (2.52 in.) Bolt Pitch Type:

      SST
      09213-54015
      09330-00021

      Tech Tips

      For the 64 mm (2.52 in.) bolt pitch type, the part number of the installation bolt for SST (crankshaft pulley holding tool) is 91551-00850 (quantity: 2).

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

    4. A01IR8C

      Remove the bolt, chain tensioner plate and spring.

    5. A01IRELE01
      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. A01ISKF

      Remove the crankshaft position sensor plate.

  30. REMOVE CRANKSHAFT TIMING GEAR KEY


    1. A01IS9HE02
      Text in Illustration
      *1 Protective Tape

      Using a screwdriver, remove the 2 crankshaft timing gear keys.

      Tech Tips

      Tape the screwdriver tip before use.

      Note

      Be careful not to damage the crankshaft.

  31. INSPECT CAMSHAFT TIMING GEAR ASSEMBLY


    1. Inspect the lock of the camshaft timing gear.

    2. A01IP7RE01
      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. A01INW8

      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. A01IOAJ

      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. A01IP59E01
      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. A01ISUX

      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. A01IR7S

      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. A01IRY1

      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.

      • A01IPE0E02

        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. A01ITPM

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

      Note


      • A01INM5E06

        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. A01IT6PE01
      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. A01IS6YE01
      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.

      A01IU8FE01

    1. A01IOOEE01

      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. A01IQT4E01
      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. A01IQQQ

      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. A01IQSV

      Remove the bolt.

    3. A01IRA4

      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. A01IQTV

      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. A01IQSME01
      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. Remove the valve lift control actuator connector from the valve rocker shaft.

      Tech Tips

      There are two types of valve lift control actuator connectors. One type is removed by rotating the connector, and the other type can be removed without being rotated.

  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. A01INKW

      Remove the 16 valve rocker arms.

      Tech Tips

      Arrange the removed parts in the correct order.

  42. REMOVE VALVE LASH ADJUSTER ASSEMBLY


    1. A01IUFME01

      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. A01IN4D

      Remove the 16 valve stem caps.

      Tech Tips

      Arrange the removed parts in the correct order.

  44. REMOVE CYLINDER HEAD SUB-ASSEMBLY


    1. A01INZXE01

      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. A01INE0E01

      Remove the cylinder head gasket.

  46. REMOVE VENTILATION VALVE SUB-ASSEMBLY


    1. A01INC9

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

  47. REMOVE OIL PAN DRAIN PLUG


    1. A01IOV0

      Remove the drain plug and gasket.

  48. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY


    1. A01IT5H

      Remove the 10 bolts and 2 nuts.

    2. A01IRYD

      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. A01ITKC

      Remove the 3 bolts and oil pump.

  50. REMOVE STIFFENING CRANKCASE ASSEMBLY


    1. A01IPHU

      Uniformly loosen and remove the 11 bolts.

    2. A01IQ0XE02
      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. A01IUNK

      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. A01IRU0

      Remove the engine rear oil seal from the cylinder block.