Engine Unit (For Sedan) Disassembly

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

Remove the nut and remove the knock sensor.

Using a 24 mm (0.94 in.) deep socket wrench, remove the oil pressure switch.

Using SST, remove the engine coolant temperature sensor.

SST

09817-33190

Remove the 2 nuts and remove the water inlet.

Remove the thermostat.

Remove the gasket from the thermostat.

Remove the oil filler cap from the cylinder head cover.

Using a screwdriver with its tip wrapped in protective tape, remove the gasket from the oil filler cap.

Remove the bolt and the crankshaft position sensor.

Remove the ventilation valve from the cylinder head cover.

Remove the 9 bolts, 2 nuts and 2 seal washers and then remove the cylinder head cover sub-assembly.

Remove the gasket from the cylinder head cover.

Remove the bolt and the camshaft timing oil control valve.

Remove the bolt and the oil level dipstick guide.

Using SST, hold the pump pulley.

SST

09960-10010(09962-01000,09963-00700)

Remove the 3 bolts and the pump pulley.

Set the No. 1 cylinder to TDC/compression.

1. Turn the crankshaft damper sub-assembly, and align its timing notch with timing mark "0" of the oil pump.
   





2. Check that the timing marks on the camshaft timing sprocket and the camshaft timing gear are all facing upward, as shown in the illustration.
   If not, turn the crankshaft 1 complete revolution (360°) and align the marks as above.
   

Using 2 SSTs, loosen the bolt while holding the crankshaft damper sub-assembly.

SST

09213-14010(91651-60865)
09330-00021

NOTICE:

Check the SST installation positions when installing them, to avoid the SST fixing bolts from coming into contact with the oil pump assembly.

Remove the SSTs and the bolt.

Remove the crankshaft damper sub-assembly.

Remove the 4 bolts and remove the transverse engine engine mounting bracket.

Remove the 3 bolts and 2 nuts and remove the water pump and gasket.

Remove the 15 bolts and nut.

Using a screwdriver with its tip wrapped in protective tape, prize the oil pump assembly to remove it.

NOTICE:

Do not damage the contact surface of the oil pump assembly and oil pan sub-assembly.

Remove the 2 O-rings from the cylinder block and oil pan sub-assembly.

Using a screwdriver with its tip wrapped in protective tape, remove the oil seal.

Pull up the stopper plate and hold it with its lock released.

Unlock the plunger of the tensioner and push it in to the end.

Pull down the stopper plate with the plunger pushed to the end and lock the plunger.

Insert a 3 mm (0.12 in.) diameter bar into the hole in the stopper plate and lock the plunger.

Remove the 2 bolts and remove the No. 1 chain tensioner assembly.

Remove the chain tensioner slipper.

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

Remove the 3 bolts and remove the fuel delivery pipe sub-assembly together with the 4 fuel injectors.

NOTICE:

Do not drop the fuel injectors when removing the fuel delivery pipe sub-assembly.

Remove the 2 No. 1 delivery pipe spacers.

Remove the 4 injector vibration insulators.

Pull the 4 fuel injector assemblies out of the fuel delivery pipe sub-assembly.

Remove the bolt and the camshaft position sensor.

Using several steps, loosen and remove the 11 bearing cap bolts uniformly in the sequence shown in the illustration, then remove the No. 1 camshaft bearing cap, No. 2 camshaft bearing cap and No. 2 camshaft.

NOTICE:

Loosen each bolt uniformly while keeping the camshaft level.

Clamp the camshaft in a vise.

Remove the fringe bolt and the camshaft timing sprocket.

NOTICE:

Do not damage the camshaft.

Using several steps, loosen and remove the 8 bearing cap bolts uniformly in the sequence shown in the illustration, then remove the No. 2 camshaft bearing cap and the camshaft.

NOTICE:

Loosen each bolt uniformly keeping the camshaft level.

Clamp the camshaft in a vise, and confirm that it is locked.

NOTICE:

Do not damage the camshaft.

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

HINT:

One of the 2 grooves located on the cam journal is for retarding cam timing (upper) and the other is for advancing cam timing (lower). Each groove has 2 oil paths. Plug one of the oil paths for each groove with a piece rubber before wrapping the cam journal with the tape.

Puncture the tape covering the advance oil path and the retard oil path on the opposite side from the advance oil path.

Apply compressed air at about 150 kPa (1.5 kgf*cm²) pressure into the 2 broken paths (the advance side path and the retard side path).

NOTICE:

Cover the paths with a piece of cloth to prevent oil splashes.

Confirm that the camshaft timing gear assembly revolves in the timing advance direction when the air pressure on the timing retard path is reduced.

HINT:

The lock pin is released and the camshaft timing gear revolves in the advance direction.

When the camshaft timing gear reaches the most advanced position, release the air pressure on the timing retard side path, and then release the air pressure on the timing advance side path.

NOTICE:

Camshaft timing gear assembly occasionally shifts to the retard side abruptly if the air pressure on the advance side path is released first. It often results in the breakage of the lock pin.

Remove the fringe bolt and remove the camshaft timing gear assembly.

NOTICE:

1. Do not remove the other 4 bolts.
   
2. When reusing the camshaft timing gear, unlock the lock pin inside the camshaft timing gear first.
   

Using several steps, loosen and remove the 10 cylinder head bolts uniformly with an 8 mm (0.31 in.) bi-hexagon wrench in the sequence shown in the illustration. Remove the 10 cylinder head bolts and the plate washers.

NOTICE:

1. Do not drop the washers into the cylinder head.
   
2. Head warpage or cracking could result from removing bolts in the wrong order.
   

Using SST, remove the oil filter.

SST

09228-06501

Using a 12 mm (0.47 in.) hexagon wrench, remove the oil filter union.

Using a knife, cut off the oil seal lip.

Using a screwdriver with its tip wrapped in protective tape, pry out the oil seal.

NOTICE:

After removal, check the crankshaft for any damage. If damaged, smooth the surface with 400-grit sandpaper.

Remove the oil pan drain plug and gasket.

Remove the 9 bolts and 2 nuts.

Insert the blade of oil pan seal cutter between the No. 1 oil pan and No. 2 oil pan, and cut off the applied sealer and remove No. 2 oil pan.

NOTICE:

Do not damage the No. 1 oil pan or No. 2 oil pan.

Remove the bolt and 2 nuts.

Remove the oil strainer and the gasket.

Loosen and remove the 13 bolts uniformly in several steps.

Using a screwdriver, remove the No. 1 oil pan by prying between the cylinder block and No. 1 oil pan.

NOTICE:

Do not damage the contact surfaces of the No. 1 oil pan or the cylinder block.

Remove the 2 O-rings from the cylinder block.

Remove the 4 stud bolts.