Part 2

ENGINE UNIT

COMPONENTS:

DISASSEMBLY (STEPS 21-40)
21. REMOVE CRANKSHAFT POSITION SENSOR
22. REMOVE CAMSHAFT TIMING PULLEY

a. Using SST, remove the bolt and the RH timing pulley.
SST 09960-10010 (09962-01000, 09963-01000)

b. Using SST, remove the bolt and the LH timing pulley.
SST 09960-10010 (09962-01000, 09963-01000)

HINT: Arrange the camshaft timing pulleys (RH and LH sides) so that they can be returned to the original locations when reassembling.

23. REMOVE TIMING BELT NO. 3 COVER
24. REMOVE TIMING BELT IDLER BRACKET

25. REMOVE CRANKSHAFT TIMING PULLEY
a. Remove the bolt and the timing belt plate.
b. Install the pulley bolt to the crankshaft.
c. Using SST, remove the crankshaft timing pulley.
SST 09950-50013 (09951-05010, 09952-05010, 09953-05020, 09954-05011)

NOTICE:
^ Do not scratch the sensor part of the crankshaft timing pulley.
^ Before using SST, apply lubricating oil to the threads and tip of the SST center bolt 150.

26. REMOVE WATER PUMP ASSEMBLY (a) Remove the 3 bolts and 3 nuts, then remove the water pump and the gasket.
27. REMOVE CAMSHAFT

NOTICE: Since the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being removed. If the camshaft is not kept level, damage to the cylinder head or to the camshaft may result. To avoid this, the following steps should be carried out.

a. Align the timing marks (2-dot marks) of the camshaft drive and the driven gears by turning the camshaft with a wrench.

b. Secure the exhaust camshaft sub-gear to the main gear with a service bolt.
Torque: 5.4 Nm (55 kgf-cm, 48 inch lbs.)

Recommended Service Bolt:

HINT: When removing the camshaft, make certain that the torsional spring force of the sub-gear has been eliminated by installation of the service bolt.

c. Using several steps, loosen and remove the 10 bearing cap bolts uniformly in the sequence shown in the illustration. Remove the 5 bearing caps and the camshaft.

NOTICE:
^ Do not pry out the camshaft.
^ Be careful not to damage the portion of the cylinder head receiving the shaft thrust.

28. REMOVE No. 2 CAMSHAFT
a. Using several steps, loosen and remove the 10 bearing cap bolts uniformly in the sequence shown in the illustration. Remove the 5 bearing caps and the No. 2 camshaft.

NOTICE:
^ Do not pry out the camshaft.
^ Be careful not to damage the portion of the cylinder head receiving the shaft thrust.

b. Remove the oil seal from the No. 2 camshaft.
29. REMOVE NO. 3 CAMSHAFT SUB-ASSEMBLY

NOTICE: Since the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being removed. If the camshaft is not kept level, damage to the cylinder head or to the camshaft may result. To avoid this, the following steps should be carried out.

a. Align the timing marks (1-dot marks) of the camshaft drive and the driven gears by turning the camshaft with a wrench.

b. Secure the exhaust camshaft sub-gear to the main gear with a service bolt.
Torque: 5.4 Nm (55 kgf-cm, 48 inch lbs.)

Recommended Service Bolt:

HINT: When removing the camshaft, make certain that the torsional spring force of the sub-gear has been eliminated by installation of the service bolt.

c. Using several steps, loosen and remove the 10 bearing cap bolts uniformly in the sequence shown in the illustration. Remove the 5 bearing caps and the No. 3 camshaft.

NOTICE:
^ Do not pry out the camshaft.
^ Be careful not to damage the portion of the cylinder head which receiving the shaft thrust.

30. REMOVE NO. 4 CAMSHAFT SUB-ASSEMBLY
a. Using several steps, loosen and remove the 10 bearing cap bolts uniformly in the sequence shown in the illustration. Remove the 5 bearing caps and the No. 4 camshaft.

NOTICE:
^ Do not pry out the camshaft.
^ Be careful not to damage the portion of the cylinder head which receiving the shaft thrust.

b. Remove the oil seal from the No. 4 camshaft.
31. INSPECT CAMSHAFT TIMING GEAR ASSEMBLY

a. Clamp the camshaft in a vise on the hexagonal lobe.
b. Check that the VVT-i will not turn.

c. Cover all the oil ports with vinyl tape except the port on the advance angle side (nearest to the convex portion) shown in the illustration.
d. Using the air gun, apply about 100 kPa (1 kgf/cm2, 14 psi) of air pressure to the port on the advance angle side.

NOTICE: Some oil spraying will occur. Be prepared to catch the spray with a shop rag.

HINT: This operation releases the lock pin for the most retard angle lock.

e. Under the condition above, turn VVT-i to the advance angle side (the white arrow marked direction in the illustration) by hand.
Standard: Must turn

HINT: Depending on the air pressure, the VVT-i will turn to the advance angle side without applying force by hand. Also, if the pressure can be hardly applied because of the air leakage from the port, it might be difficult to get the lock-pin to release.

f. Check that the VVT-i moves freely within about 30° range. Avoid moving the VVT-i unit to the most retard angle position as the lock-pin will reengage.
Standard: Smooth movable range is about 30°
g. Turn the VVT-i by hand and lock it at the most retard angle position.
32. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY

NOTICE: Do not remove or install the camshaft timing gear (VVT-i) unless you are replacing the VVT-i or the camshaft.

a. Clamp the camshaft in a vise on the hexagonal lobe.

NOTICE: Be careful not to damage the camshaft.

b. Using a 46 mm socket wrench, remove the lock nut by turning it clockwise.

NOTICE:
^ Remove it with the lock-pin engaged and locked at the most retard angle position.
^ The lock nut has LH threads.
^ Never use any tool other than the socket wrench. Other tools will deform the cam angle rotor.

c. Remove the camshaft VVT-i.

NOTICE: Never remove the 3 bolts on the gear.

If it is difficult to remove VVT-i, tap it lightly using a plastic-faced hammer and then remove it.
33. REMOVE CAMSHAFT SUB GEAR

a. Clamp the camshaft in a vise on the hexagonal lobe.

NOTICE: Be careful not to damage the camshaft.

b. Using SST, turn the sub-gear counterclockwise, and remove the service bolt.
SST 09960-10010 (09962-01000, 09963-00500)

c. Using snap ring pliers, remove the snap ring.
d. Remove the wave washer, camshaft sub-gear and camshaft gear bolt washer.

HINT: Arrange the camshaft sub-gears and gear bolt washers (RH and LH sides) so that they can be returned to the original location when reassembling.

34. REMOVE ENGINE HANGER No. 2
35. REMOVE CYLINDER HEAD COVER REAR

36. REMOVE OIL CONTROL VALVE FILTER
a. Remove the plug, gasket and valve filter.
37. REMOVE CYLINDER HEAD SUB-ASSEMBLY

a. Using a socket hexagon wrench 8, remove the hexagon bolt.

b. Using several steps, loosen the 8 cylinder head bolts uniformly in the sequence shown in the illustration. Remove the 8 cylinder head bolts and plate washers.

NOTICE:
^ Be careful not to drop the washers into the cylinder head.
^ Head warpage or cracking could result from removing bolts in an incorrect order.

38. REMOVE CYLINDER HEAD GASKET
39. REMOVE CYLINDER HEAD LH

a. Using a socket hexagon wrench 8, remove the hexagon bolt.