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OVERHAUL

HINT: Thoroughly clean all parts to be assembled.

- Before installing the parts, apply new engine oil to all sliding and rotating surfaces.
- Replace all gaskets, O-rings and oil seals with new parts.

1. REMOVE ENGINE HANGER NO.1
a) Remove the 2 bolts and engine hanger No. 1.
2. REMOVE ENGINE HANGER NO.2
a) Remove the 2 bolts and engine hanger No. 2.
3. REMOVE OIL LEVEL GAUGE GUIDE
a) Remove the bolt and pull out the oil level gauge guide.
b) Remove the O-ring from the oil level gauge guide.
4. REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSY
a) Remove the 2 water drain cocks.
5. REMOVE VVT SENSOR
a) Remove the 2 bolts and 2 VVT sensors.
6. REMOVE CRANKSHAFT POSITION SENSOR
a) Remove the bolt and crankshaft position sensor.

7. REMOVE OIL CONTROL VALVE FILTER
a) Remove the plug, filter and gasket from each cylinder head.

8. REMOVE CYLINDER HEAD COVER SUB-ASSY
a) Remove the 10 bolts, 3 seal washers, 2 nuts, cylinder head cover and gasket.

9. REMOVE CYLINDER HEAD COVER SUB-ASSY LH
a) Remove the 10 bolts, 3 seal washers, 2 nuts, cylinder head cover and gasket.
b) Remove the ventilation valve from the cylinder head cover.

10. REMOVE CRANKSHAFT PULLEY
a) Turn the crankshaft pulley, and align the notch with the timing mark "0" of the timing chain cover.

b) Check that the timing marks of the camshaft timing gears are aligned with the timing marks of the bearing cap as shown in the illustration.
If not, turn the crankshaft 1 complete revolution (360°) and align the timing marks as above.

c) Using SST, hold the crankshaft pulley and loosen the pulley set bolt.
SST 09213-54015 (91651-60855), 09330-00021

d) Using the pulley set bolt and SST, remove the crankshaft pulley.
SST 09950-50013 (09951-05010, 09952-05010, 09953-05020, 09954-05030)
11. REMOVE OIL PAN DRAIN PLUG
a) Remove the drain plug and gasket.

2. REMOVE OIL PAN SUB-ASSY NO.2
a) Remove the 10 bolts and 2 nuts.

b) Insert the blade of SST between the oil pan and oil pan No. 2, cut off applied sealer and remove the oil pan No. 2.
SST 09032-00100

NOTICE:
- Be careful not to damage the contact surface of the oil pan and oil pan No. 2.
- Be careful not to damage the oil pan No. 2 flange.

13. REMOVE OIL STRAINER SUB-ASSY
a) Remove the 2 nuts, oil strainer and gasket.

14. REMOVE OIL PAN SUB-ASSY
a) Remove 17 bolts and 2 nuts.

b) Using a screwdriver, remove the oil pan by prying between the oil pan and cylinder block in the sequence shown.

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

c) Remove the O-ring from the oil pump.

15. REMOVE WATER PUMP ASSY
a) Remove the 17 bolts, water pump and gasket.

16. REMOVE TIMING CHAIN OR BELT COVER SUB-ASSY
a) Remove the 15 bolts and 2 nuts.

b) 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 timing chain cover, cylinder block and cylinder head.

c) Remove the O-ring from the LH cylinder head.

17. REMOVE TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL
a) Using a screwdriver, pry out the oil seal.

NOTICE: Be careful not to damage the oil pump assembly. Wrap a tip of the screwdriver with tape.

18. REMOVE CHAIN TENSIONER ASSY NO. 1

NOTICE:
- Never rotate the crankshaft with the chain tensioner removed.
- When rotating the camshaft with the timing chain removed, rotate the crankshaft counterclockwise 40° from the TDC first.

a) While turning the stopper plate of the tensioner upward, push in the plunger of the chain tensioner as shown in the illustration.
b) While turning the stopper plate of the tensioner downward, insert a bar of 3.5 mm (0.138 inch) into the holes in the stopper plate and tensioner to fix the stopper plate.
c) Remove the 2 bolts and chain tensioner.
19. REMOVE CHAIN TENSIONER SLIPPER

20. REMOVE IDLE GEAR NO.1
a) Using a 10 mm hexagon wrench, remove the idle gear shaft No. 2, idle gear No. 1 and idle gear shaft No. 1.
21. REMOVE CHAIN VIBRATION DAMPER NO. 2
a) Remove the 2 chain vibration damper No. 2.
22. REMOVE CHAIN SUB-ASSY
23. REMOVE CRANKSHAFT TIMING GEAR OR SPROCKET
24. REMOVE CHAIN VIBRATION DAMPER NO. 1
a) Remove the 2 bolts and chain vibration damper No. 1.

25. REMOVE CAMSHAFT TIMING GEARS AND NO.2 CHAIN (RH BANK)
a) While raising up the chain tensioner No. 2, insert a pin of 1.0 mm (0.039 inch) into the hole to fix it.

b) Hold the hexagonal portion of the camshaft with a wrench, and remove the 2 bolts, camshaft timing gear, camshaft timing gear assembly and timing chain No. 2.

NOTICE:
- Be careful not to damage the cylinder head and valve lifter with the wrench.
- Do not disassemble the camshaft timing gear assembly.

26. REMOVE CHAIN TENSIONER ASSY NO.2
a) Remove the bolt and chain tensioner No. 2.

27. REMOVE CAMSHAFT TIMING GEARS AND NO.2 CHAIN (LH BANK)
a) While pushing down the chain tensioner No. 3, insert a pin of 1.0 mm (0.039 inch) into the hole to fix it.

28. REMOVE CHAIN TENSIONER ASSY NO.3.
a) Remove the bolt and chain tensioner No. 3.
29. REMOVE CAMSHAFTS

NOTICE: As 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, the portion of the cylinder head which are received the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, the following steps should be carried out.

a) Remove the camshafts of the RH bank.
1) Rotate the camshafts counterclockwise using the wrench so that the cam lobes of No. 1 cylinder face each direction as shown in the illustration.

2) Using several steps, loosen and remove the 16 bearing cap bolts uniformly in the sequence as shown in the illustration.
3) Remove the 8 bearing caps and 2 camshafts.

b) Remove the camshafts of the LH bank.
1) Using several steps, loosen and remove the 16 bearing cap bolts uniformly in the sequence as shown in the illustration.
2) Remove the 8 bearing caps and 2 camshafts.
30. REMOVE CAMSHAFT BEARING NO. 1
31. REMOVE CAMSHAFT BEARING NO.2

32. REMOVE CYLINDER HEADS
a) Using several steps, remove the 2 cylinder head bolts on the LH cylinder head in the sequence as shown in the illustration.

b) Using several steps, loosen the 8 cylinder head bolts on each cylinder head with a 10 mm bi-hexagon wrench in the sequence as shown in the illustration. Remove the 16 cylinder head bolts and plate washers.

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

c) Lift the cylinder head from the dowels on the cylinder block, and place the 2 cylinder heads on wooden blocks on a bench.

NOTICE: Be careful not to damage the contact surfaces of the cylinder head and cylinder block.

HINT: If the cylinder head is difficult to lift off, pry between the cylinder head and cylinder block with a screwdriver.

d) Remove the RH and LH cylinder head gaskets.

33. REMOVE WATER OUTLET PIPE NO.1
a) Separate the knock sensor wire.
b) Remove the bolt, 2 nuts and water outlet pipe.