ENGINE UNIT > DISASSEMBLY

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1. Remove the oil filler cap.
   

1. Remove the oil filler cap gasket.
   

1. Remove the 3 engine cover joint bolts.
   

1. Remove the bolt and wiring harness clamp bracket.
   

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

1. Remove the bolt and camshaft position sensor.
   

1. Remove the bolt and camshaft timing oil control valve.
   

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

1. Remove the bolt and crankshaft position sensor.
   

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

1. Remove the bolt and knock sensor.
   

1. Remove the engine coolant temperature sensor and gasket.
   

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

   NOTICE:

   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. Remove the 2 gaskets from the camshaft bearing cap.
   

1. Remove the cylinder head cover gasket.
   

1. Pry up the 4 claws of the ventilation baffle plate.
   

   NOTICE:

   Do not deform the claws of the baffle plate more than necessary.

2. Remove the 4 gaskets from the cylinder head cover.
   

   HINT:

   Prevent the plug tube gaskets from being deformed as much as possible. The removed gaskets will be used when installing new gaskets.

   NOTICE:

   Be careful not to damage the cylinder head cover.

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.
   

   Text in Illustration 

   *1	Cap Rib
   *2	Oil Filter Bracket Clip

   SST

   09228-06501  
   

   NOTICE:

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

   HINT:

   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.
   

   Text in Illustration 

   *1	Oil Filter Element
   *2	O-ring

   NOTICE:

   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.

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

NOTICE:

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

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

   Text in Illustration 

   *1	Timing Mark
   *2	Timing Notch

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.
   

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

   Text in Illustration 

   *a	Hold
   *b	Turn

   SST

   09213-58014   (91551-80840)
   09330-00021  
   

2. Using SST, remove the crankshaft pulley and pulley bolt.
   

   Text in Illustration 

   *a	Hold
   *b	Turn

   SST

   09950-50013   (09951-05010, 09952-05010, 09953-05020, 09954-05021)
   

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

   NOTICE:

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

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.
   

   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.
   

   Text in Illustration 

   *1	Protective Tape

   NOTICE:

   1. Be careful not to damage the contact surfaces of the timing chain cover, cylinder block, and cylinder head.
      
   2. Pry the timing chain cover out evenly in order to prevent damaging the knock pins.
      

   HINT:

   Tape the screwdriver tip before use.

6. Remove the 3 O-rings.
   

1. Place the timing chain cover on wooden blocks.
   

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

   Text in Illustration 

   *1	Protective Tape
   *2	Wooden Block

   HINT:

   Tape the screwdriver tip before use.

   NOTICE:

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

1. Remove the chain tensioner slipper from the cylinder block.
   

1. Remove the 2 bolts and chain vibration damper.
   

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

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.
   

   HINT:

   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.
   

1. Remove the crankshaft timing sprocket.
   

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.
   

   SST

   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.
   

   Text in Illustration 

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

1. Remove the crankshaft position sensor plate.
   

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

   Text in Illustration 

   *1	Protective Tape

   HINT:

   Tape the screwdriver tip before use.

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.
   

   Text in Illustration 

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

   NOTICE:

   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.
   

   NOTICE:

   1. If air leaks out, reattach the adhesive tape.
      
   2. 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).
   

   HINT:

   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.
   

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

   Text in Illustration 

   *1	Flange Bolt
   *a	Do not remove

   NOTICE:

   1. Before removing the camshaft timing gear, make sure that the lock pin has been released.
      
   
   
   2. Be sure not to remove the other 4 bolts.
      
   3. Keep the camshaft timing gear horizontal while removing it from the camshaft.
      

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

   Text in Illustration 

   *1	Flange Bolt
   *a	Do not remove

   NOTICE:

   1. Before removing the camshaft timing gear, make sure that the lock pin has been released.
      
   
   
   2. Be sure not to remove the other 4 bolts.
      
   3. Keep the camshaft timing gear horizontal while removing it from the camshaft.
      

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.
   

   NOTICE:

   Uniformly loosen the bearing cap bolts while keeping the camshaft housing level.

3. Remove the 5 bearing caps.
   

   HINT:

   Arrange the removed parts in the correct order.

1. Remove the camshaft.
   

1. Remove the No. 2 camshaft.
   

NOTICE:

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

1. Remove the 16 valve rocker arms.
   

   HINT:

   Arrange the removed parts in the correct order.

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

   HINT:

   Arrange the removed parts in the correct order.

1. Remove the 16 valve stem caps.
   

   HINT:

   Arrange the removed parts in the correct order.

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

1. Remove the 2 camshaft bearings.
   

1. Remove the 2 camshaft bearings.
   

1. Remove the 2 bolts.
   

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

   Text in Illustration 

   *1	Protective Tape

   NOTICE:

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

   HINT:

   Tape the screwdriver tip before use.

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.
   

   NOTICE:

   1. Be careful not to drop washers into the cylinder head.
      
   2. 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.
   

   NOTICE:

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

1. Remove the cylinder head gasket.
   

1. Remove the ventilation valve sub-assembly.
   

1. Remove the drain plug and gasket.
   

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.
   

   NOTICE:

   Be careful not to damage the contact surfaces of the crankcase, chain cover and oil pan.

1. Remove the 3 bolts and oil pump.
   

1. Uniformly loosen and remove the 11 bolts.
   

2. Using a screwdriver, remove the stiffening crankcase by prying between the stiffening crankcase and cylinder block.
   

   Text in Illustration 

   *1	Protective Tape

   HINT:

   Tape the screwdriver tip before use.

   NOTICE:

   Be careful not to damage the contact surfaces of the crankcase and cylinder block.

1. Remove the 2 No. 1 taper screw plugs.
   

NOTICE:

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

NOTICE:

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

1. Remove the engine rear oil seal from the cylinder block.