Engine Unit Disassembly

Remove the oil filler cap.

Remove the gasket from the oil filler cap.

Remove the 2 engine cover joints.

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

Remove the 2 bolts and 2 sensors.

Remove the 2 bolts, O-rings, bracket and 2 oil control valves.

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

NOTICE:

Be careful not to drop any of the gaskets into the engine when removing the cylinder head cover because the gaskets may stick to the cylinder head cover.

Remove the cylinder head cover gasket.

Remove the 3 gaskets from the camshaft bearing cap.

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

Check that each timing mark of the camshaft timing gear and sprocket are aligned with each timing mark located as shown in the illustration. If not, turn the crankshaft 1 revolution (360°) to align the timing marks as shown in the illustration.

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

SST

09213-58014(91551-80840)
09330-00021

NOTICE:

Check the SST installation positions when installing them to prevent the SST fixing bolts from coming into contact with the timing chain cover sub-assembly.

Using SST, remove the crankshaft pulley and pulley bolt.

SST

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

Remove the 2 nuts, bracket, tensioner and gasket.

NOTICE:

Do not turn the crankshaft without the chain tensioner installed.

Remove the bolt and sensor.

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

Remove the 2 No. 1 taper screw plugs.

Remove the bolt and sensor.

Using a 19 mm deep socket wrench, remove the sensor.

Remove the gasket from the engine coolant temperature sensor.

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

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.

Remove the oil filter cap assembly.

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

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.

Remove the 3 bolts and engine mounting bracket.

Remove the 4 bolts and oil filter bracket.

Remove the 2 O-rings.

Remove the 19 bolts.

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

NOTICE:

Be careful not to damage the contact surfaces of the timing chain cover, cylinder block, and cylinder head.

HINT:

Tape the screwdriver tip before use.

Remove the 3 O-rings.

Remove the 3 bolts and water pump.

Remove the gasket.

Using a screwdriver and hammer, remove the oil seal.

NOTICE:

Be careful not to damage the timing chain cover.

HINT:

Tape the screwdriver tip before use.

Remove the 3 bolts, gasket and inlet water housing.

Remove the 4 bolts and No. 1 generator bracket.

Remove the chain tensioner slipper.

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

Hold the hexagonal portion of the camshaft with a wrench and turn the camshaft timing gear assembly counterclockwise to loosen the chain between the camshaft timing gears.

With the chain loosened, release the chain from the camshaft timing gear assembly and place it on the camshaft timing gear assembly.

HINT:

Be sure to release the chain from the sprocket completely.

Turn the camshaft clockwise to return it to the original position and remove the chain.

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

Remove the crankshaft timing sprocket.

Temporarily tighten the crank pulley bolt.

Turn the crankshaft 90° clockwise to align the adjusting hole of the oil pump drive shaft sprocket with the groove of the oil pump.

NOTICE:

Do not rotate the crankshaft more than 90°. If the crankshaft is rotated too much without the timing chain installed, the valves may hit the pistons and cause damage.

Remove the crank pulley bolt.

Insert a 3 mm diameter bar into the adjusting hole of the oil pump drive shaft sprocket to lock the gear in position, and then remove the nut.

Remove the bolt, chain tensioner plate, and spring.

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

Remove the No. 1 crankshaft position sensor plate.

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

HINT:

Tape the screwdriver tip before use.

Check the lock of the camshaft timing gear.

Release the lock pin.

NOTICE:

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

1. 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.
   

   NOTICE:

   Be sure to cover the oil hole completely because air leaks due to insufficient sealing will prevent the lock pin from being released.

2. Prick a hole in the tape covering the oil hole as shown in the illustration. (Procedure A)
   





3. 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.
      
   3. Do not lock the camshaft timing gear assembly. If it is locked, release the lock pin again.
      

   HINT:

   1. The camshaft timing gear assembly may be turned in the advance direction without applying any force.
      
   2. If enough air pressure cannot be applied because of air leakage from the port, releasing the lock pin may be difficult.
      

4. Remove the adhesive tape from the No. 1 camshaft bearing cap.
   

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

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 assembly horizontal while removing it from the camshaft.
   

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

NOTICE:

1. Be sure not to remove the other 4 bolts.
   
2. Keep the camshaft timing exhaust gear assembly horizontal while removing it from the camshaft.
   

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

Uniformly loosen and remove the 15 bearing cap bolts in the sequence shown in the illustration.

NOTICE:

Uniformly loosen the bolts while keeping the camshaft level.

Remove the 5 bearing caps.

HINT:

Arrange the removed parts in the correct order.

Remove the camshaft.

Remove the No. 2 camshaft.

Remove the 16 valve rocker arms.

HINT:

Arrange the removed parts in the correct order.

Remove the 16 valve lash adjusters from the cylinder head.

HINT:

Arrange the removed parts in the correct order.

Remove the oil control valve filter.

Remove the 2 No. 1 camshaft bearings.

Remove the 2 No. 2 camshaft bearings.

Remove the 2 bolts.

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

NOTICE:

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

HINT:

Tape the screwdriver tip before use.

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

NOTICE:

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

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.

Remove the cylinder head gasket.

Remove the ventilation valve.

Remove the oil pan drain plug and gasket.

Remove the 10 bolts and 2 nuts.

Insert the blade of 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 and oil pan.

Remove the 3 bolts and oil pump.

Using a knife, cut off the oil seal lip.

Using a screwdriver with its tip taped, pry out the oil seal.

NOTICE:

After removing the oil seal, check the crankshaft for damage. If it is damaged, smooth the surface with 400-grit sandpaper.

Uniformly loosen and remove the 11 bolts.

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

NOTICE:

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