Part 2

PARTIAL ENGINE ASSEMBLY (CONTINUED)
OVERHAUL

26. REMOVE WATER PUMP ASSEMBLY
a. Remove the 3 bolts, the 3 nuts, 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 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 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 VVT-i will not turn.

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

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

HINT: Perform this in order to release the lock pin for the maximum delay 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, 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 maximum delay angle position as the lock-pin will re-engage.
Standard: Smooth movable range is about 30°
g. Turn VVT-i by hand and lock it at the maximum delay angle position.
32. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY

NOTICE: Do not remove or install the camshaft timing gear (VVT-i) unless you are changing 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 maximum delay 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, the camshaft sub-gear and the 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 re-assembling.

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

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

a. Using an 8 mm hexagon wrench, 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 the plate washers.

NOTICE:
^ Be careful not to drop 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 an 8 mm hexagon wrench, remove the hexagon bolt.

41. REMOVE WATER INLET HOUSING
a. Remove the 8 bolts, the 2 nuts and the water inlet housing.

42. REMOVE OIL FILTER SUB-ASSEMBLY
a. Using SST, remove the oil filter.
SST 09228-07501
b. Using a 12 mm socket hexagon wrench, remove the oil filter union.
43. REMOVE OIL PAN DRAIN PLUG
44. REMOVE OIL PAN SUB-ASSEMBLY NO.2

a. Remove the 10 bolts and the 2 nuts.

b. Insert the blade of SST between oil pan No. 1 and oil pan No. 2, cut off the sealer and remove the oil pan No. 2.
SST 09032-00100

NOTICE:
^ Be careful not to damage the contact surface of oil pan No. 1 where oil pan No. 2 is mounting.
^ Do not damage flange portion of oil pan No. 2 when removing.

45. REMOVE OIL STRAINER SUB-ASSEMBLY
a. Remove the bolt, the 2 nuts, the oil strainer and the gasket.
46. REMOVE OIL PAN SUB-ASSEMBLY

a. Loosen and remove the 15 bolts and the 2 nuts uniformly.

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

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

47. REMOVE OIL PAN BAFFLE PLATE

48. REMOVE ENGINE REAR OIL SEAL RETAINER
a. Remove the 6 bolts.
b. Using a screwdriver, remove the oil seal retainer by prying between the oil seal retainer and the main bearing cap.

49. REMOVE ENGINE REAR OIL SEAL
a. Using a screwdriver and a hammer, tap out the oil seal.

50. REMOVE OIL PUMP ASSEMBLY
a. Remove the 9 bolts.
b. Using a screwdriver, remove the oil pump by prying between the oil pump and the main bearing cap.
c. Remove the O-ring.