Engine Unit Disassembly

Using a 16 mm spark plug wrench, remove the 4 spark plugs.

Remove the oil filler cap sub-assembly.

Remove the gasket from the oil filler cap sub-assembly.

Disconnect the PCV hose from the PCV valve.

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

Disconnect the camshaft position sensor connector.

Remove the bolt and camshaft position sensor.

Disconnect the camshaft position sensor connector.

Remove the bolt and camshaft position sensor.

Disconnect the crankshaft position sensor connector and detach the wire harness clamp.

Remove the bolt and crankshaft position sensor.

Detach the 2 clamps and disconnect the 2 connectors.

Remove the bolt and disconnect the wiring harness clamp bracket.

Disconnect the camshaft timing oil control valve connector.

Remove the bolt and camshaft timing oil control valve assembly.

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

Disconnect the camshaft timing oil control valve connector.

Remove the bolt and camshaft timing oil control valve assembly.

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

Slide the clip and disconnect the PCV hose from the PCV valve sub-assembly.

Remove the 21 bolts, 2 nuts, 2 plate washers, 2 seal washers and cylinder head cover sub-assembly.

Remove the gasket from the cylinder head cover sub-assembly.

Remove the No. 1 camshaft bearing cap oil hole gasket from the cylinder head cover spacer.

Remove the 2 bolts and No. 1 ventilation connector from the cylinder head cover sub-assembly.

Remove the bolt and 2 nuts, and then remove the water inlet.

Remove the gasket from the timing chain cover sub-assembly.

Remove the thermostat from the timing chain cover sub-assembly.

Remove the gasket from the thermostat.

Using SST, hold the crankshaft pulley and loosen the pulley bolt until 2 or 3 threads are screwed into the crankshaft.

SST

09213-54015(91651-60855)
09330-00021

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

SST

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

HINT:

Apply lubricant to the threads and end of SST.

Remove the 2 No. 1 oil pan plugs and oil pan cover silencer.

Remove the oil pan drain plug and gasket.

Remove the 16 bolts, 2 adjusting screws, and 2 nuts.

Insert the blade of an oil pan seal cutter between the oil pans. Cut through the applied sealer and remove the No. 2 oil pan sub-assembly.

NOTICE:

Be careful not to damage the contact surfaces of the oil pans.

Remove the 16 bolts and 2 nuts.

Remove the oil pan sub-assembly by prying between the oil pan sub-assembly and cylinder block with a screwdriver.

NOTICE:

Be careful not to damage the contact surfaces of the cylinder block and oil pan sub-assembly.

HINT:

Tape the screwdriver tip before use.

Remove the gasket from the oil strainer sub-assembly.

Remove the 6 bolts, oil strainer sub-assembly and gasket.

Remove the 6 bolts.

Using a screwdriver, pry out the rear engine oil seal retainer.

HINT:

Tape the screwdriver tip before use.

Place the rear engine oil seal retainer on wooden blocks.

Using a screwdriver and hammer, tap out the rear engine oil seal.

HINT:

Tape the screwdriver tip before use.

Disconnect the engine oil pressure switch assembly connector.

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

Disconnect the knock sensor connector.

Remove the bolt and knock sensor.

Disconnect the engine coolant temperature sensor connector.

Using a 19 mm deep socket wrench, remove the engine coolant temperature sensor and gasket.

Using SST, remove the oil filter sub-assembly.

SST

09228-07501

Slide the 2 clips and remove the No. 4 water by-pass hose from the oil cooler assembly and union.

Disconnect the No. 5 water by-pass hose from the oil cooler assembly.

Remove the 2 bolts and No. 4 water by-pass pipe.

Slide the 2 clamps and disconnect the No. 4 water by-pass hose and No. 5 water by-pass hose from the oil cooler assembly.

Remove the oil cooler union bolt, plate washer and oil cooler assembly.

Remove the O-ring from the oil cooler assembly.

Using a 27 mm socket wrench, remove the oil filter union.

Remove the 2 bolts and nut from the oil filter bracket.

Remove the 2 screw plugs and 2 gaskets from the oil filter bracket.

Remove the oil filter bracket gasket and O-ring.

Using a hexagon wrench, remove the oil filter bracket union.

Remove the union from the cylinder block.

Remove the No. 1 taper screw plug from the cylinder block.

Remove the 2 bolts and V-ribbed belt tensioner assembly.

Remove the 16 bolts and nut shown in the illustration.

Using a screwdriver wrapped in protective tape, remove the timing chain cover sub-assembly by prying the points in the illustration.

NOTICE:

Do not damage the surrounding parts.

HINT:

Tape the screwdriver tip before use.

Remove the 3 O-rings from the timing chain cover sub-assembly.

Remove the 8 bolts, engine water pump assembly and gasket.

Using a screwdriver wrapped in protective tape, pry out the timing chain cover oil seal from the timing chain cover sub-assembly.

NOTICE:

Be careful not to damage the timing chain cover sub-assembly.

HINT:

Tape the screwdriver tip before use.

Temporarily install the crankshaft pulley bolt.

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

HINT:

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

Remove the crankshaft pulley bolt.

Remove the 2 bolts and cylinder head cover connector sub-assembly.

Remove the No. 2 camshaft bearing cap oil hole gasket and 3 No. 3 camshaft bearing cap oil hole gaskets from the No. 1 camshaft bearing cap.

Remove the 2 bolts, timing chain guide and O-ring.

Move the stopper plate upward to release the lock and push the plunger deep into the tensioner.

Move the stopper plate downward to set the lock and insert a hexagon wrench into the stopper plate hole.

Remove the bolt, nut, No. 1 chain tensioner assembly and gasket.

Remove the bolt and chain tensioner slipper.

Remove the bolt, nut and No. 1 chain vibration damper.

Remove the crankshaft timing gear or sprocket from the crankshaft.

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

NOTICE:

Uniformly loosen the bolts while keeping the camshaft level.

Remove the 9 bearing caps.

HINT:

Arrange the removed parts in the correct order.

Remove the camshaft.

Remove the No. 2 camshaft.

Remove the 16 No. 1 valve rocker arm sub-assemblies from the cylinder head sub-assembly.

HINT:

Arrange the removed parts in the correct order.

Remove the 16 valve lash adjuster assemblies from the cylinder head sub-assembly.

HINT:

Arrange the removed parts in the correct order.

Remove the 16 valve stem caps from the cylinder head sub-assembly.

HINT:

Arrange the removed parts in the correct order.

Check the lock of the camshaft timing gear assembly.

1. Using SST, grip the hexagonal portion, and then secure SST and camshaft in a vise as shown in the illustration and check that the camshaft timing gear assembly does not rotate.
   

   SST

   09212-31010
   

   Text in Illustration

   *a	Hexagonal Portion

   NOTICE:

   1. Do not damage the camshaft.
      
   2. Never grip areas other than the hexagonal portion, as this may cause damage.
      

Release the lock pin.

1. Clean the camshaft journal with non-residue solvent.
   





2. Cover the 4 oil paths of the cam journal with vinyl tape as shown in the illustration.
   

   Text in Illustration

   *a	Retard Side Path
   *b	Advance Side Path
   *c	Open
   *d	Close
   	Rubber Piece
   	Vinyl Tape

   HINT:

   1 retard side path and 1 advance side path are provided in the groove of the camshaft. Plug one of the paths with a rubber piece.

3. Break through the tape over the advance side path, and then break through the tape over the retard side path on the opposite side from the hole over the advance side path as shown in the illustration.
   





4. Apply compressed air at approximately 200 kPa (2.0 kgf/cm², 28 psi) to the 2 open paths accessible through the holes in the tape.
   

   Text in Illustration

   *a	Retard Side Path
   *b	Advance Side Path

   NOTICE:

   Cover the paths with a piece of cloth when applying pressure to keep oil from splashing.





5. Check that the camshaft timing gear assembly revolves in the advance direction when reducing the air pressure applied to the retard side path.
   

   OK:

   Gear rotates in the advance direction.
   

   Text in Illustration

   *a	Retard Side Path
   *b	Advance Side Path
   *c	Decompress
   *d	Hold Pressure

   HINT:

   This operation releases the lock pin which holds the timing gear in the most retarded position.

6. When the camshaft timing gear assembly reaches the most advanced position, release the air pressure from the retard side path and advance side path in that order.
   

   NOTICE:

   1. Do not release the air pressure from the advance side path first. The gear may abruptly shift in the retard direction and break the lock pin.
      
   2. When releasing the air pressure from the advance side path, release it slowly.
      

Check for smooth rotation.

1. Rotate the camshaft timing gear assembly within its movable range several times, but do not turn it to the most retarded position. Check that the gear rotates smoothly.
   

   CAUTION:

   Do not use air pressure to perform the smooth operation check.

Check the lock in the most retarded position.

1. Confirm that the camshaft timing gear assembly becomes locked at the most retarded position.
   

Using SST, grip the hexagonal portion, and then secure SST and camshaft in a vise as shown in the illustration.

SST

09212-31010

NOTICE:

1. Do not damage the camshaft.
   
2. Never grip areas other than the hexagonal portion, as this may cause damage.
   

Remove the flange bolt and camshaft timing gear assembly.

NOTICE:

1. Be sure not to remove the other 3 bolts.
   
2. If planning to reuse the gear, be sure to release the straight pin lock before installing the gear.
   

Check the lock of the camshaft timing exhaust gear assembly.

1. Using SST, grip the hexagonal portion, and then secure SST and No. 2 camshaft in a vise as shown in the illustration and check that the camshaft timing exhaust gear assembly does not rotate.
   

   SST

   09212-31010
   

   Text in Illustration

   *a	Hexagonal Portion

   NOTICE:

   1. Do not damage the No. 2 camshaft.
      
   2. Never grip areas other than the hexagonal portion, as this may cause damage.
      

Release the lock pin.

1. Clean the No. 2 camshaft journal with non-residue solvent.
   

2. Cover the 4 oil paths of the cam journal with vinyl tape as shown in the illustration.
   

   Text in Illustration

   *a	Retard Side Path
   *b	Advance Side Path
   *c	Open
   *d	Close
   	Rubber Piece
   	Vinyl Tape

   HINT:

   There are 4 oil paths in the grooves of the No. 2 camshaft. Plug 2 paths with pieces of rubber.

3. Break through the tape over the advance side path, and then break through the tape over the retard side path on the opposite side from the hole over the advance side path as shown in the illustration.
   





4. Apply compressed air at approximately 200 kPa (2.0 kgf/cm², 28 psi) to the 2 open paths (the advance side path and retard side path).
   

   Text in Illustration

   *a	Retard Side Path
   *b	Advance Side Path

   NOTICE:

   Cover the paths with a piece of cloth when applying pressure to keep oil from splashing.

   HINT:

   The lock pin is released in this condition.





5. Check that the camshaft timing exhaust gear assembly turns in the retard direction when reducing the air pressure applied to the advance side path.
   

   Text in Illustration

   *a	Retard Side Path
   *b	Advance Side Path
   *c	Decompress
   *d	Hold Pressure

   HINT:

   The lock pin is released and the camshaft timing exhaust gear assembly turns in the retard direction.

6. When the camshaft timing exhaust gear assembly moves to the most retarded position, release the air pressure from the advance side path, and then release the air pressure from the retard side path.
   

   NOTICE:

   Be sure to release the air pressure from the advance side path first. If the air pressure of the retard side path is released first, the camshaft timing exhaust gear assembly may abruptly shift in the advance direction and break the lock pin or other parts.

Check for smooth rotation.

1. Turn the camshaft timing exhaust gear assembly within its movable range (21.5 to 23.5°) 2 or 3 times, but do not turn it to the most advanced position. Make sure that the gear turns smoothly.
   

   NOTICE:

   When the air pressure is released from the advance side path and then from the retard side path, the gear automatically returns to the most advanced position due to the advance assist spring operation, and locks. Gradually release the air pressure from the retard side path before performing the smooth rotation check.

Check the lock at the most advanced position.

1. Make sure that the camshaft timing exhaust gear assembly locks at the most advanced position.
   

Using SST, grip the hexagonal portion, and then secure SST and No. 2 camshaft in a vise as shown in the illustration.

SST

09212-31010

NOTICE:

1. Do not damage the No. 2 camshaft.
   
2. Never grip areas other than the hexagonal portion, as this may cause damage.
   

Remove the flange bolt and camshaft timing exhaust gear assembly.

NOTICE:

Be sure not to remove the other 4 bolts.

w/ Oil Cooler:
Remove the bolt and disconnect the No. 4 water by-pass pipe.

Uniformly loosen the 10 cylinder head set bolts in the sequence shown in the illustration. Remove the 10 cylinder head set bolts and plate washers.

NOTICE:

1. Be careful not to drop plate washers into the cylinder head sub-assembly.
   
2. Head warpage or cracking could result from removing cylinder head set bolts in the incorrect order.
   

Remove the cylinder head sub-assembly.

Remove the cylinder head gasket from the cylinder block.

Using an 8 mm hexagon wrench, remove the screw plug.

Remove the oil control valve filter and gasket.

Move the stopper plate downward to release the lock and push the plunger deep into the tensioner.

Move the stopper plate upward to set the lock and insert a hexagon wrench into the stopper plate hole.

Remove the bolt and No. 2 chain vibration damper.

Remove the 2 bolts and No. 3 chain vibration damper.

Remove the hexagon wrench from the No. 2 chain tensioner assembly.

Remove the nut and No. 2 chain tensioner assembly.

Remove the bolt, balanceshaft drive gear shaft and balanceshaft drive gear sub-assembly.

Remove the crankshaft timing sprocket and No. 2 chain sub-assembly.

Remove the 2 bolts and No. 4 chain vibration damper.

Remove the 2 crankshaft pulley set keys from the crankshaft.