Engine Unit Disassembly

Remove the oil filler cap.

Remove the oil filler cap gasket.

Remove the 2 engine cover joints.

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

Remove the 2 bolts and 2 camshaft position sensors.

Remove the 2 bolts, wire harness bracket and 2 camshaft timing oil control valves.

Remove the 2 O-rings from the camshaft timing oil control valves.

Remove the bolt and crankshaft position sensor.

Disconnect the oil pressure switch connector.

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

Remove the bolt and knock sensor.

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

SST

09817-33190

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

Remove the 3 gaskets from the camshaft bearing cap.

NOTICE:

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.

Remove the cylinder head cover gasket.

Pry up the 4 claws of the ventilation baffle plate.

NOTICE:

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

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.

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

HINT:

Set a container below the oil filter cap before loosening the oil filter cap.

NOTICE:

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

Remove the oil filter cap.

Remove the 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.

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

Check that timing marks on both the camshaft timing exhaust gear and camshaft timing gear are facing upward as shown in the illustration.

HINT:

If not, turn the crankshaft 1 complete revolution (360°) and align the marks as above.

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.

SST

09213-58014(91551-80840)
09330-00021

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

SST

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

HINT:

Apply lubricant to the threads and end of SST.

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

NOTICE:

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

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, camshaft housing, cylinder block and stiffening crankcase with a screwdriver as shown in the illustration.

HINT:

Tape the screwdriver tip before use.

NOTICE:

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

Remove the 3 O-rings.

Remove the 3 bolts and water pump.

Remove the gasket.

Place the timing chain cover on wooden blocks.

Using a screwdriver, tap out the oil seal.

HINT:

Tape the screwdriver tip before use.

NOTICE:

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

Remove the 3 bolts, water inlet housing and gasket.

Remove the 4 bolts and generator bracket.

Remove the chain tensioner slipper from the cylinder block.

Remove the 2 bolts and chain vibration damper.

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.

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.

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

Remove the crankshaft timing sprocket.

Temporarily install the crankshaft pulley with the pulley bolt.

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

SST

09213-58014(91551-80840)
09330-00021

Remove SST, the crankshaft pulley bolt and crankshaft pulley.

Remove the bolt, chain tensioner plate and spring.

Remove the oil pump drive gear, oil pump drive shaft gear and No. 2 chain.

Remove the 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.

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.

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

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.
   

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.

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.

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

Check the lock of the camshaft timing exhaust gear.

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.

NOTICE:

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

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

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.

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.
   

Using a screwdriver with its tip wrapped with tape, forcibly turn the camshaft timing exhaust gear in the retard direction (clockwise).

NOTICE:

1. 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.
   
2. Do not damage the camshaft timing exhaust gear.
   

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.

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

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

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.
   

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

NOTICE:

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

Remove the 2 bolts and valve rocker arm lost motion damper.

NOTICE:

1. Make sure the camshaft housing is installed to the cylinder head when removing or installing a valve rocker arm lost motion damper.
   
2. If a valve rocker arm lost motion damper is removed, do not remove the camshaft housing.
   
3. Do not remove the shims. If a shim is removed, replace the camshaft housing as engine malfunctions may result from irregular valve timing.
   

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}

Add engine oil into the hole for engine oil.

Uniformly loosen and remove the 17 bearing cap bolts in the sequence shown in the illustration.

NOTICE:

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

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

HINT:

Tape the screwdriver tip before use.

NOTICE:

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

Using a screwdriver, slide the control actuator clip from the control actuator connector.

NOTICE:

Slide only the upper part of the control actuator clip, as the straight pin may fall if the control actuator clip is completely removed.

Remove the bolt.

Using a screwdriver, lightly pry the control actuator connector to make a space between the continuously variable valve lift controller and camshaft housing.

NOTICE:

1. Do not forcefully pry the control actuator connector.
   
2. Do not damage the camshaft housing or camshaft bearing cap.
   

Using a magnet hand, remove the straight pin from the control actuator connector.

HINT:

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.

Remove the continuously variable valve lift controller from the camshaft housing.

Remove the O-ring from the continuously variable valve lift controller.

NOTICE:

The O-ring may remain on the camshaft housing side. Be sure to always remove it.

Rotate the control actuator connector and remove it from the valve rocker shaft.

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 16 valve stem caps.

HINT:

Arrange the removed parts in the correct order.

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.
   

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 drain cock plug from the drain cock.

Remove the water drain cock from the cylinder block.

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

Remove the drain plug and gasket.

Remove the 10 bolts and 2 nuts.

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:

1. Be careful not to damage the surface of the oil pan which contacts the stiffening crankcase.
   
2. Be careful not to damage the stiffening crankcase flange.
   

Remove the 3 bolts and oil pump.

Uniformly loosen and remove the 11 bolts.

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

HINT:

Tape the screwdriver tip before use.

NOTICE:

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

Remove the screw plug.

Remove the engine rear oil seal from the cylinder block.