Engine Unit Disassembly

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

Disconnect the engine oil pressure switch connector.

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

Disconnect the sensor connector.

Remove the bolt and sensor.

Disconnect the sensor connector.

Remove the sensor.

Remove the gasket from the sensor.

Remove the oil filler cap.

Remove the gasket from the oil filler cap.

Loosen the hose clamp and disconnect the PCV hose from the PCV valve sub-assembly.

Remove the PCV valve sub-assembly.

Disconnect the sensor connector.

Remove the bolt and sensor.

Disconnect the sensor connector.

Disconnect the connector from the connector bracket.

Detach the harness clamp.

Remove the bolt and sensor.

Disconnect the oil control valve connector.

Remove the bolt and oil control valve.

Remove the O-ring from the oil control valve.

Remove the 19 bolts, 2 nuts, cylinder head cover and 2 gaskets.

Disconnect the power steering pump connector.

Remove the 2 nuts, bolt and water inlet.

Remove the gasket from the timing chain cover.

Remove the thermostat from the timing chain cover.

Remove the gasket from the thermostat.

Turn the crankshaft pulley, and align its groove with timing mark 0 of the timing chain cover.

Check that the timing marks of the camshaft timing gear and sprocket are aligned with the timing marks of the No. 1 bearing cap, as shown in the illustration.

Using SST, loosen the pulley bolt.

SST

09213-54015(91651-60855)
09330-00021

Using SST, remove the pulley bolt and pulley.

SST

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

Remove the drain plug and gasket.

Remove the 20 bolts 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.

NOTICE:

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

Remove the bolt, 2 nuts, oil strainer and gasket.

Remove the 16 bolts and 2 nuts.

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

NOTICE:

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

HINT:

Tape the screwdriver tip before use.

Remove the O-ring.

Remove the 3 bolts and tensioner.

Remove the 19 bolts and 2 nuts shown in the illustration.

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 cylinder head, cylinder block and timing chain cover.

HINT:

Tape the screwdriver tip before use.

Remove the 3 O-rings.

Using a 10 mm socket hexagon wrench, remove the timing gear case plug.

Remove the 8 bolts, engine water pump and gasket.

Place the timing chain cover on wooden blocks.

Using a screwdriver pry out the front crankshaft oil seal.

HINT:

Tape the screwdriver tip before use.

Using a 27 mm socket wrench, remove the plug and gasket.

Remove the valve spring and relief valve.

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, 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, chain tensioner and gasket.

Remove the bolt and tensioner slipper.

Remove the 2 bolts and vibration damper.

Remove the crankshaft timing sprocket from the crankshaft.

Uniformly loosen and remove the 21 bearing cap bolts in the sequence shown in the illustration.

NOTICE:

Uniformly loosen the bolts while keeping the camshafts level.

Remove the oil delivery pipe and O-ring from the bearing caps.

Remove the 9 bearing caps.

HINT:

Arrange the removed parts in the correct order.

Remove the 16 valve rocker arms from the cylinder head.

HINT:

Arrange the removed parts in the correct order.

Mount the camshaft in a vise and remove the sprocket bolt and camshaft timing sprocket.

NOTICE:

Do not damage the camshaft.

Check the lock of the camshaft timing gear.

1. Mount the camshaft in a vise and confirm that the camshaft timing gear is locked.
   

   Text in Illustration

   *1	Retard Side Path
   *2	Advance Side Path
   *a	Open
   *b	Close
   	Rubber Piece
   	Vinyl Tape

   NOTICE:

   Do not damage the camshaft.

Release the lock pin.

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

   HINT:

   2 advance side paths are provided in the groove of the camshaft. Plug one of the paths with a rubber piece.

2. 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.
   





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

   Text in Illustration

   *1	Retard Side Path
   *2	Advance Side Path

   CAUTION:

   Some oil splashing will occur. Cover the paths with a piece of cloth.





4. Check that the camshaft timing gear 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

   *1	Retard Side Path
   *2	Advance Side Path
   *a	Decompress
   *b	Hold Pressure

   HINT:

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

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

   NOTICE:

   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.

Check for smooth rotation.

1. Rotate the camshaft timing gear 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 becomes locked at the most retarded position.
   

Remove the flange bolt of the camshaft timing gear.

NOTICE:

Be sure not to remove the other 3 bolts.

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

NOTICE:

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

Remove the cylinder head gasket from the cylinder block.

Move the stopper plate downward to release the lock and push the plunger deep into the No. 2 chain tensioner.

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

Remove the bolt and chain vibration damper.

Remove the 2 bolts and chain vibration damper.

Remove the hexagon wrench from the tensioner assembly.

Remove the nut and chain tensioner assembly.

Remove the bolt, balance shaft drive gear shaft and balance shaft drive gear.

Remove the No. 2 crankshaft timing sprocket and chain.

Remove the 2 bolts and vibration damper.

Remove the 2 pulley set keys from the crankshaft.

Using SST, remove the oil filter.

SST

09228-07501

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 taper screw plug from the cylinder block.

Remove the 6 bolts.

Using a screwdriver, pry off the oil seal retainer.

HINT:

Tape the screwdriver tip before use.

Place the oil seal retainer on wooden blocks.

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

HINT:

Tape the screwdriver tip before use.

Remove the 16 valve stem caps from the cylinder head.

HINT:

Arrange the removed parts in the correct order.

Place the lash adjuster into a container full of new engine oil.

Insert the tip of SST into the lash adjuster plunger and use the tip to press down on the check ball inside the plunger.

SST

09276-75010

Squeeze SST and the lash adjuster together to move the plunger up and down 5 to 6 times.

Check the movement of the plunger and bleed air.

OK:

Plunger moves up and down.

NOTICE:

When bleeding high-pressure air from the compression chamber, make sure that the tip of SST is actually pressing the check ball as shown in the illustration. If the check ball is not pressed, air will not bleed.

After bleeding the air, remove SST. Then try to quickly and firmly press the plunger with your fingers.

OK:

Plunger can be pressed 3 times.

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

Remove the oil control valve filter and gasket.