Part 1
PZEV:
Except PZEV:
PARTIAL ENGINE ASSY
OVERHAUL
1. REMOVE OIL FILTER SUB-ASSY
a) Using SST, remove the oil filter.
SST 09228-06501
2. REMOVE OIL FILTER UNION
a) Using a 12 mm hexagon wrench, remove the union.
3. REMOVE OIL FILLER CAP SUB-ASSY
4. REMOVE VENTILATION VALVE SUB-ASSY
5. REMOVE SPARK PLUG
6. REMOVE CYLINDER HEAD COVER SUB-ASSY
a) Remove the 8 bolts, 2 nuts and cylinder head cover.
7. REMOVE CYLINDER HEAD COVER GASKET
8. REMOVE CRANKSHAFT POSITION SENSOR
9. REMOVE CRANKSHAFT PULLEY
a) Turn the crankshaft pulley and align its groove with timing mark 0 of the timing chain cover.
b) Check that the timing marks of the camshaft timing gear and sprockets are aligned with the timing marks of bearing caps No. 1 and No. 2, as shown in the illustration.
c) Remove the crankshaft pulley.
1) Using applicable SST, fix the pulley and loosen the bolt.
2) Using applicable SST, remove the bolt and pulley.
10. REMOVE CHAIN TENSIONER ASSY NO.1
a) Remove the 2 nuts, chain tensioner and gasket.
NOTICE: Do not turn the crankshaft without the chain tensioner.
11. REMOVE WATER PUMP PULLEY
a) Using SST, remove the water pump pulley.
SST 09960-10010 (09962-01000, 09963-00700)
12. REMOVE WATER PUMP ASSY
a) Remove the 4 bolts, 2 nuts, bracket and water pump.
13. REMOVE OIL PAN DRAIN PLUG
14. REMOVE OIL PAN SUB-ASSY
a) Remove the 12 bolts and 2 nuts.
b) Insert the blade of SST between the crankcase and oil pan. Cut off applied sealer and remove the oil pan.
SST 09032-00100
NOTICE: Be careful not to damage the contact surface of the cylinder block and oil pan.
15. REMOVE TIMING CHAIN OR BELT COVER SUB-ASSY
a) Remove the 14 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.
16. REMOVE TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL
a) Using a screwdriver and a hammer, remove the oil seal.
17. REMOVE CRANKSHAFT POSITION SENSOR PLATE NO.1
18. REMOVE TIMING CHAIN GUIDE
19. REMOVE CHAIN TENSIONER SLIPPER
20. REMOVE CHAIN VIBRATION DAMPER NO.1
21. REMOVE CHAIN SUB-ASSY
22. REMOVE CRANKSHAFT TIMING GEAR OR SPROCKET
23. REMOVE NO.2 CHAIN SUB-ASSY
a) Turn the crankshaft counterclockwise by 90°, and align the adjusting hole of the oil pump driven sprocket with the groove of the oil pump.
b) Put a bar ([diameter] 4 mm (0.157 inch)) in the adjusting hole of the oil pump driven sprocket to temporarily lock the sprocket in position. Remove the nut.
c) Remove the bolt, chain tensioner plate and spring.
d) Remove the oil pump drive sprocket, oil pump driven sprocket and chain.
24. REMOVE OIL PUMP ASSY
a) Remove the 3 bolts, oil pump and gasket.
25. REMOVE NO.2 CAMSHAFT
a) Uniformly loosen and remove the camshaft's 10 bearing cap bolts in the sequence shown in the illustration. Then remove the 5 bearings.
b) Remove the camshaft.
26. REMOVE CAMSHAFT
a) Uniformly loosen and remove the camshaft's 10 bearing cap bolts in the sequence shown in the illustration. Then remove the 5 bearings.
b) Remove the camshaft.
27. REMOVE CAMSHAFT BEARING NO.1
28. REMOVE CAMSHAFT TIMING SPROCKET
a) Fix the camshaft in a vise and remove the camshaft timing sprocket.
NOTICE: Be careful not to damage the camshaft.
29. REMOVE CAMSHAFT TIMING GEAR ASSY
a) Fix the camshaft in a vise, and make sure that the camshaft timing gear does not move.
b) Cover all the oil ports with vinyl tape except the advanced angle side shown in the illustration.
c) Using an air gun, apply about 150 kPa (1.5 kgf-cm, 21 psi) of air pressure to the port on the advanced angle side.
CAUTION: Some oil spraying will occur. Contain the spray with a shop rag.
HINT: This operation releases the lock pin for the extreme retarded angle lock.
d) Under the condition above, check that the camshaft timing gear can be turned by hand to the advanced angle side (counterclockwise), the direction of the arrow in the illustration.
Standard: Can be turned
HINT: The camshaft timing gear 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.
e) Remove the fringe bolt from the camshaft timing gear.
NOTICE:
^ Be sure not to remove the other 4 bolts.
^ If planning to reuse the camshaft timing gear, release the straight pin lock first, and then install the gear.
30. REMOVE CAMSHAFT BEARING NO.2
31. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSY
32. REMOVE CYLINDER HEAD SUB-ASSY
a) Using a 10 mm bi-hexagon wrench, uniformly loosen the 10 bolts in the sequence shown in the illustration. Remove the 10 cylinder head bolts and 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.
33. REMOVE CYLINDER HEAD GASKET