Steps 1-35

ENGINE UNIT

COMPONENTS:

DISASSEMBLY (STEPS 1-35)
1. DRAIN ENGINE OIL
2. REMOVE SPARK PLUG
3. REMOVE VENTILATION VALVE SUB-ASSEMBLY
4. REMOVE OIL FILLER CAP SUB-ASSEMBLY
5. REMOVE OIL FILLER CAP GASKET

6. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY
a. Remove the 2 engine wire harness clamps [A].
b. Remove the 3 nuts and disconnect the engine wire harness [B].
c. Remove the 9 bolts and cylinder head cover.
7. REMOVE CYLINDER HEAD COVER GASKET

8. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH
a. Using an E6 torx socket wrench, remove the 2 bolts and disconnect the engine wire harness protector.
b. Remove the 9 bolts and cylinder head cover.
9. REMOVE CYLINDER HEAD COVER GASKET NO. 2
10. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY
11. REMOVE VVT SENSOR
a. Remove the sensor.
b. Remove the O-ring from the sensor.
12. REMOVE OIL LEVEL GAGE SUB-ASSEMBLY
13. REMOVE OIL LEVEL GAGE GUIDE

14. REMOVE CRANKSHAFT PULLEY
a. Using SST, loosen the pulley bolt.
SST 09213-54015 (91651-60855), 09330-00021

b. Using SST and the pulley bolt, remove the pulley.
SST 09950-50013 (09951-05010, 09952-05010, 09953-05020, 09954-05031)

NOTICE: Before using SST, apply lubricating oil to the threads and tip of the center bolt 150.

15. REMOVE TIMING BELT NO. 1 COVER

16. REMOVE TIMING BELT NO. 2 COVER
a. Disconnect the engine wire protector clamps from the timing belt No. 3 cover.
b. Remove the 5 bolts and timing belt cover.
17. REMOVE ENGINE MOUNTING BRACKET RH
18. REMOVE TIMING BELT GUIDE NO. 2

19. REMOVE TIMING BELT
a. Set the No. 1 cylinder to TDC/compression.
(1) Temporarily install the crankshaft pulley bolt and washer to the crankshaft.
(2) Turn the crankshaft clockwise, and align the timing mark of the crankshaft timing pulley with the oil pump body.

(3) Check that timing marks of the camshaft timing pulleys and No. 3 timing belt cover are aligned. If not, turn the crankshaft 1 revolution (360°).
(4) Remove the crankshaft pulley bolt.

b. If planning to reuse the timing belt, check that there are 4 installation marks on the timing belt, as shown in the illustration.
(1) If the installation marks have disappeared, put new installation marks on the timing belt before removing.

c. Set the No. 1 cylinder to approximately 60° BTDC/compression.
(1) Turn the crankshaft counterclockwise by approximately 60°.

NOTICE: With the timing belt removed: The crankshaft pulley must be at the correct angle to avoid damage in later steps. If the crankshaft pulley is at the wrong angle and the camshaft timing pulley and the camshaft are removed, the piston head and valve head may come in contact and damaged.

d. Remove the timing belt tensioner.

NOTICE: Do not reinstall the tensioner with its plunger extended.

e. Remove the timing belt in this order.
20. REMOVE TIMING BELT IDLER SUB-ASSEMBLY NO. 1
a. Using a socket hexagon wrench 10, remove the pivot bolt, timing belt idler No. 1 and plate washer.
21. REMOVE TIMING BELT IDLER SUB-ASSEMBLY NO. 2
22. REMOVE CRANKSHAFT POSITION SENSOR

23. REMOVE CAMSHAFT TIMING PULLEY
a. Using SST, remove the bolt and RH timing pulley.
SST 09960-10010 (09962-01000, 09963-01000), 09249-63010

b. Using SST, remove the bolt and 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.

24. REMOVE TIMING BELT NO. 3 COVER
a. Disconnect the 3 engine wire harness clamps from the timing belt No. 3 cover.
b. Remove the 6 bolts and the timing belt cover.
25. REMOVE TIMING BELT IDLER BRACKET

26. 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 center bolt 150.

27. REMOVE WATER PUMP ASSEMBLY
a. Remove the 3 bolts and 3 nuts, then remove the water pump and the gasket.
28. 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, these steps must be carried out.

a. Align the camshaft drive and driven gear's timing marks (2 dot marks each) by turning the camshaft with a wrench.

b. Secure the exhaust camshaft sub gear to the main gear with a service bolt.

Recommended Service Bolt:

Torque: 5.0 Nm (51 kgf-cm, 44 inch lbs.)

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. Uniformly loosen and remove the 10 bearing cap bolts 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.

29. REMOVE NO. 2 CAMSHAFT
a. Uniformly loosen and remove the 10 bearing cap bolts 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.
30. 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, these steps should be carried out.

a. Align the camshaft drive and driven gear's timing marks (1 dot mark each) by turning the camshaft with a wrench.

Recommended Service Bolt:

b. Secure the exhaust camshaft sub gear to the main gear with a service bolt.
Torque: 5.0 Nm (51 kgf-cm, 44 inch lbs.)

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. Uniformly loosen and remove the 10 bearing cap bolts 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.

31. REMOVE NO. 4 CAMSHAFT SUB-ASSEMBLY
a. Uniformly loosen and remove the 10 bearing cap bolts 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.

32. INSPECT CAMSHAFT TIMING GEAR ASSEMBLY
a. Clamp the camshaft in a vise on the hexagonal lobe.
b. Check that the VVT-i does not turn.

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

NOTICE: Some oil will spill out. Contain the oil with a shop rag.

HINT: This operation releases the lock pin for the extreme retarded angle lock.

e. Under the condition above, check that the VVT-i can be turned by hand to the advanced angle side, the direction of the white arrow in the illustration.
Standard: Must turn

HINT: The VVT-i will turn to the advanced angle side without applying force by hand depending on the force of the air pressure applied. Also, if applying pressure to the oil path is difficult as a result of air leakage from the port, the lock-pin may be difficult to release.

f. Check that the VVT-i moves freely within a 30° range. Avoid moving the VVT-i unit to the extreme retarded 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 extreme retarded angle position.
33. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY

NOTICE: Do not remove or install the 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: Do not 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 extreme retarded angle position.
^ The lock nut has LH threads.
^ Only use the socket wrench. Other tools will deform the cam angle rotor.

c. Remove the timing gear (VVT-i).

NOTICE: Never remove the 3 bolts on the gear. If it is difficult to remove the VVT-i, tap it lightly using a plastic-faced hammer and then remove it.

34. 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 their original location when reassembled.

35. REMOVE ENGINE HANGER NO. 2