Part 1
OVERHAUL1. REMOVE OIL FILLER CAP SUB-ASSY
2. REMOVE OIL FILLER CAP GASKET
a. Using a screwdriver, remove the gasket from the oil filter cap.
3. REMOVE VENTILATION VALVE SUB-ASSY
4. REMOVE SPARK PLUG
5. REMOVE CYLINDER HEAD COVER SUB-ASSY
a. Remove the 9 bolts and cylinder head cover.
b. Remove the spark plug tube gasket and O-ring.
6. REMOVE CYLINDER HEAD COVER GASKET
7. REMOVE WATER PUMP PULLEY
a. Using SST remove the water pump pulley
SST 09960-10010 (09962-01000, 09963-00600)
8. REMOVE WATER PUMP ASSY
a. remove the 6 bolts, water pump and O-ring.
9. REMOVE TRANSVERSE ENGINE ENGINE MOUNTING BRACKET
10. SET NO. 1 CYLINDER TO TDC/COMPRESSION
a. Turn the crankshaft pulley, and align its groove with timing mark "0" of the timing chain cover.
b. Check that the point marks of the camshaft timing sprocket and VVT timing sprocket are in straight line on the timing chain cover surface as shown in the illustration.
HINT: If not, turn the crankshaft 1 revolution (360°) and align the marks.
11. REMOVE CRANKSHAFT PULLEY
a. Using SST, remove the pulley bolt.
SST 09213-70011 (09213-70020), 09330-00021
b. Using SST, remove the crankshaft pulley.
SST 09950-50013 (09951-05010, 09952-05010, 09953-05020, 09954-05021)
12. REMOVE CHAIN TENSIONER ASSY NO.1
a. Remove the 2 nuts and chain tensioner.
NOTICE: Be sure not to revolve the crankshaft without the chain tensioner.
13. REMOVE TIMING CHAIN OR BELT COVER SUB-ASSY
a. Remove the 13 bolts.
b. Remove the stud bolt.
NOTICE: Be careful not to damage the contact surfaces of the timing chain cover, cylinder head and cylinder block.
14. REMOVE TIMING GEAR COVER OIL SEAL
a. Using a screwdriver, remove the oil seal.
15. REMOVE CRANKSHAFT POSITION SENSOR PLATE NO.1
16. REMOVE CHAIN TENSIONER SLIPPER
a. Remove the bolt and chain tensioner slipper.
17. REMOVE CHAIN VIBRATION DAMPER NO.1
a. Remove the 2 bolts and chain vibration damper No.l.
18. REMOVE CHAIN SUB-ASSY
a. Using screwdrivers, ply out the timing chain with the crankshaft timing gear as shown in the illustration.
NOTICE:
^ Put shop rag to protect the engine.
^ In case of revolving the camshafts with the chain off the sprockets, turn the crankshaft 1/4 revolution for valves not to touch the pistons.
19. REMOVE OIL PUMP ASSY
a. Remove the 5 bolts and oil pump.
b. Remove oil pump gasket from cylinder block.
20. REMOVE CAMSHAFT
a. Uniformly loosen and remove the 20 bearing cap bolts, in several passes, in the sequence shown, and remove the 9 bearing caps, intake and exhaust camshafts.
21. REMOVE CAMSHAFT TIMING GEAR OR SPROCKET
a. Grip the camshaft No.2 with a vice, and remove the camshaft timing gear.
NOTICE: Be careful not to damage the camshaft.
22. INSPECT CAMSHAFT TIMING GEAR ASSY
a. Check the lock of camshaft timing gear.
1 Grip the camshaft with a vice, and confirm the camshaft timing gear is locked.
NOTICE: Be careful not to damage the camshaft.
b. Release lock pin.
1 Cover 4 oil paths of cam journal with vinyl tape as shown in the illustration.
HINT: Two advance side paths are provided in the groove of the camshaft. Plug one of the path with a rubber piece.
2 Break through the tapes of the advance side path and the retard side path on the opposite side of the groove.
3 Put air pressure into two broken paths (the advance side path and the retard side path) with about 150 kPa (1.5 kgf/cm2).
CAUTION: Cover the paths with shop rag to avoid oil splashing.
4 Confirm if the camshaft timing gear assembly revolves in the timing advance direction when weakening the air pressure of the timing retard path.
HINT: The lock pin is released, and camshaft timing gear, revolves in the advance direction.
5 When the camshaft timing gear comes to the most advanced position, take out the air pressure of the timing retard side path, and then, take out that of timing advance side path.
CAUTION: Camshaft timing assembly gear occasionally shifts to the retard side abruptly, if the air compression of the advanced side path is released before retard side path. It often causes the breakage of the lock pin.
c. Check smooth revolution
1 Revolve the camshaft timing gear assembly within the movable range except for the most retarded position several times, and check the smooth revolution.
CAUTION: Be sure to perform this check by hand, instead of air pressure.
d. Check the lock in the most retarded position.
1 Confirm that the camshaft timing gear assembly is locked at the most retarded position.
23. REMOVE CAMSHAFT TIMING GEAR ASSY
a. Grip the camshaft with a vice, and confirm that the gear is locked.
CAUTION: Be careful not to damage the camshaft.
b. Cover 4 oil paths of cam journal with vinyl tape as shown in the illustration.
HINT: Two advance side paths are provided in the groove of the camshaft. Plug one of the path with a rubber piece.
c. Break through the tapes of the advance side path and the retard side path on the opposite side of the groove.
d. Put air pressure into two broken paths (the advance side path and the retard side path) with about 150 kPa (1.5 kgf/cm2).
CAUTION: Cover the paths with shop rag to avoid oil splashing.
e. Confirm if the camshaft timing gear assembly revolves in the timing advance direction when weakening the air pressure of the timing retard path.
HINT: The lock pin is released, and camshaft timing gear revolves in the advance direction.
f. When the camshaft timing gear comes to the most advanced position, take out the air pressure of the timing retard side path. and then, takeout that of timing advance side path.
CAUTION: Camshaft timing gear assembly occasionally shifts to the retard side abruptly, if the air compression of the advanced side path is released before retard side paths. It often causes the breakage of the lock pin.
g. Remove the fringe bolt of camshaft timing gear assembly.
NOTICE:
^ Be sure not to remove the other 4 bolts.
^ In case of reusing the camshaft timing gear, release the strait pin locking first, and then install the gear.
24. REMOVE CAM TIMING CONTROL VALVE HOUSING
a. Remove the 3 bolts, 2 nuts and cam timing oil control valve housing.
b. Remove cam timing oil control valve housing gasket
25. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSY
26. REMOVE OIL CONTROL VALVE FILTER
a. Remove the plug and oil control valve filter. (Front side)
b. Remove the oil control valve filter. (Rear side)
27. REMOVE VALVE ROCKER SHAFT SUB-ASSY NO.1
a. Remove the bolt and the rocker shaft No.l.
b. Remove the valve rocker arm.
28. REMOVE VALVE ROCKER SHAFT SUB-ASSY NO.2
a. Remove the bolt and the rocker shaft No.2.
b. Remove the valve rocker arm.
29. REMOVE CYLINDER HEAD SUB-ASSY
a. Using a 10 mm bi-hexagon wrench, uniformly loosen an remove the 10 cylinder head bolts, in several passes, in the sequence shown. 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.
30. REMOVE CYLINDER HEAD GASKET
31. REMOVE OIL FILTER SUB-ASSY
a. Using SST, remove the oil filter.
SST 09228-06501