Part 1
PARTIAL ENGINE ASSY
OVERHAUL
1. REMOVE SPARK PLUG
2. REMOVE OIL FILLER CAP SUB-ASSY
3. REMOVE OIL FILLER CAP GASKET
4. REMOVE CYLINDER HEAD COVER SUB-ASSY LH
5. REMOVE CYLINDER HEAD COVER GASKET NO.2
6. REMOVE CYLINDER HEAD COVER SUB-ASSY
7. REMOVE CYLINDER HEAD COVER GASKET
8. REMOVE VENTILATION VALVE SUB-ASSY
9. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSY
10. REMOVE VVT SENSOR
a. Remove the sensor.
b. Remove the O-ring from the sensor.
11. REMOVE OIL LEVEL GAGE SUB-ASSY
12. REMOVE OIL LEVEL GAGE GUIDE
13. 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 on the threads and tip of the center bolt 150.
14. REMOVE TIMING BELT NO.1 COVER
15. REMOVE TIMING BELT NO.2 COVER
16. REMOVE ENGINE MOUNTING BRACKET RH
17. REMOVE TIMING BELT GUIDE NO.2
18. 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 reusing 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 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.
19. REMOVE TIMING BELT IDLER SUB-ASSY NO.1
a. Using a socket hexagon wrench 10, remove the pivot bolt, timing belt idler No. 1 and plate washer.
20. REMOVE TIMING BELT IDLER SUB-ASSY NO.2
21. REMOVE CRANKSHAFT POSITION SENSOR
22. REMOVE CAMSHAFT TIMING PULLEY
a. Using SST, remove the bolt and RH timing pulley.
SST 09960-10010 (09962-01000, 09963-01000)
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.
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 on the threads and tip of the center bolt 150.
26. REMOVE WATER PUMP ASSY
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 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: 5.4 Nm (55 kgf-cm, 48 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.
28. 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.
29. REMOVE NO.3 CAMSHAFT SUB-ASSY
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 camshaft drive and driven gear's timing marks (1 dot mark 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: 5.4 Nm (55 kgf-cm, 48 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.
30. REMOVE NO.1 CAMSHAFT SUB-ASSY
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.
31. INSPECT CAMSHAFT TIMING GEAR ASSY
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 spraying will occur. Contain the spray 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 re-engage.
Standard: Smooth movable range is about 30°
g. Turn VVT-i by hand and lock it at the extreme retarded angle position.
32. REMOVE CAMSHAFT TIMING GEAR ASSY
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.