ENGINE UNIT > DISASSEMBLY

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1. Using a knife, cut off the oil seal lip.
   

   Text in Illustration 

   *1	Protective Tape
   *a	Cut Position

2. Using a screwdriver with its tip wrapped with protective tape, pry out the rear engine oil seal.
   

1. Using a screwdriver with its tip wrapped with protective tape, pry out the rear engine oil seal.
   

   Text in Illustration 

   *1	Protective Tape

   NOTICE:

   1. If the snap ring is broken, the ring gear may move out from its original position and result in an oil leak. Therefore, it is necessary to confirm that the snap ring is installed correctly and undamaged when replacing the oil seal.
      
   2. Be careful not to damage the crankshaft bearing.
      

1. Using SST, hold the crankshaft.
   

   SST

   09960-10010   (09962-01000, 09963-01000)
   

2. Using SST, remove the crankshaft bearing from the crankshaft.
   

   Text in Illustration 

   *a	Hold
   *b	Turn

   SST

   09950-40011   (09951-04010, 09952-04010, 09953-04020, 09954-04010, 09955-04071, 09957-04010, 09958-04011)
   09950-60010   (09951-00280, 09951-00380, 09952-06010)
   

3. Remove the snap ring from the bearing.
   

1. Remove the oil filler cap.
   

1. Remove the gasket from the oil filler cap.
   

1. Using a 14 mm spark plug wrench, remove the 4 spark plugs.
   

1. Remove the 2 bolts, 2 O-rings and the 2 camshaft timing oil control valves.
   

1. Remove the 2 bolts and the 2 No. 1 crankshaft position sensors.
   

1. Remove the ventilation valve.
   

1. Remove the ventilation system grommet from the cylinder head cover.
   

1. Remove the 18 bolts, 2 seal washers and the cylinder head cover.
   

   NOTICE:

   Be careful not to drop any of the gaskets into the engine when removing the cylinder head cover because the gaskets may stick to the cylinder head cover.

2. Remove the cylinder head cover gasket.
   

1. Remove the 2 camshaft bearing cap oil hole gaskets from the camshaft bearing cap.
   

1. Remove the bolt and the crankshaft position sensor.
   

1. Using a 24 mm deep socket wrench, remove the engine oil pressure switch.
   

1. Remove the bolt and sensor.
   

1. Using a 19 mm deep socket wrench, remove the engine coolant temperature sensor.
   

2. Remove the gasket from the engine coolant temperature sensor.
   

1. Connect a hose with an inside diameter of 15 mm (0.591 in.) to the pipe.
   

   Text in Illustration 

   *1	Pipe
   *2	Hose

2. Remove the oil filter drain plug.
   

3. Install the pipe to the oil filter cap.
   

   Text in Illustration 

   *1	Cap
   *2	Valve
   *3	Pipe
   *4	O-ring
   *5	Hose

   NOTICE:

   If the O-ring is removed with the drain plug, install the O-ring together with the pipe.

   HINT:

   Use a container to catch the draining oil.

4. Check that oil is drained from the oil filter. Then disconnect the pipe as shown in the illustration.
   

5. Remove the O-ring.
   

6. Using SST, remove the oil filter cap.
   

   SST

   09228-06501  
   

7. Remove the oil filter element and O-ring from the oil filter cap.
   

   Text in Illustration 

   *1	O-ring
   *2	Oil Filter Element

   NOTICE:

   Be sure to remove the O-ring (for the cap) by hand, without using any tools, to prevent damage to the groove.

1. Using SST, remove the 4 bolts and water pump pulley.
   

   SST

   09960-10010   (09962-01000, 09963-00600)
   

1. Turn the crankshaft pulley until its groove and the groove of the timing chain cover are aligned.
   

   Text in Illustration 

   *1	Timing Mark
   *2	Groove

2. Check that each timing mark of the camshaft timing gear and sprocket are located as shown in the illustration. If not, turn the crankshaft 1 revolution (360°) to align the timing marks as shown in the illustration.
   

1. Using SST, remove the crankshaft pulley bolt.
   

   SST

   09960-10010   (09962-01000, 09963-01000)
   

2. Remove the crankshaft pulley from the crankshaft.
   

1. Remove the 5 bolts and the water pump, water pump gasket from the timing chain cover.
   

2. Remove the 3 bolts and the engine mounting bracket.
   

3. Remove the 21 bolts and seal washer.
   

   Text in Illustration 

   *1	Seal Washer

4. Using a screwdriver with its tip wrapped with protective tape, remove the timing chain cover by prying between the timing chain cover and cylinder head or cylinder block.
   

   Text in Illustration 

   *1	Protective Tape

   NOTICE:

   Be careful not to damage the contact surfaces of the timing chain cover, cylinder block, and cylinder head.

5. Remove the 2 O-rings.
   

6. Using an 8 mm socket hexagon wrench, remove the plug.
   

1. Remove the 3 bolts and the water inlet.
   

1. Remove the No. 2 water inlet housing gasket from the water inlet.
   

1. Using a screwdriver with its tip wrapped with protective tape, remove the timing chain cover oil seal.
   

   Text in Illustration 

   *1	Protective Tape
   *2	Wooden Block

   NOTICE:

   Do not damage the surface of the oil seal press fit hole.

1. Set the camshaft timing gear, camshaft timing exhaust gear and crankshaft in the positions (20° ATDC) shown in the illustration.
   

   Text in Illustration 

   *1	Timing Mark
   *a	TDC

2. Push down on the stopper plate to release the lock and push in the plunger.
   

   Text in Illustration 

   *1	Stopper Plate
   *2	Plunger
   	Push

3. Pull up the stopper plate with the plunger pushed to the end and lock the plunger.
   

   Text in Illustration 

   *1	Stopper Plate

4. Insert a 3 mm (0.118 in.) diameter bar into the hole in the stopper plate and lock the plunger.
   

   Text in Illustration 

   *1

   Bar

5. Remove the 2 nuts and the No. 1 chain tensioner.
   

6. Remove the gasket from the cylinder head.
   

1. Remove the 2 bolts and the No. 2 chain vibration damper.
   

1. Remove the bolt and the timing chain tension arm.
   

1. Remove the chain.
   

1. Remove the 2 bolts and the timing chain guide.
   

1. Check the lock of the camshaft timing gear.
   

2. Release the lock pin.
   

   NOTICE:

   Before removing the camshaft timing gear, make sure that the lock pin has been released.

   
   

   1. After cleaning and degrease the VVT oil hole on the intake side of the No. 1 camshaft bearing cap, completely seal the oil hole with adhesive tape or equivalent as shown in the illustration to prevent air from leaking.
      

      Text in Illustration 

      *1	Prick a Hole
      *2	Adhesive Tape
      *a	Adhesive Tape Sealing Area

      NOTICE:

      Be sure to cover the oil hole completely because air leaks due to insufficient sealing will prevent the lock pin from being released.

   2. Prick a hole in the tape covering the oil hole as shown in the illustration (Procedure A).
      

   
   
   

   3. Apply approximately 150 kPa (1.5 kgf/cm², 22 psi) of air pressure to the hole pricked in procedure A to release the lock pin.
      

      NOTICE:

      1. If air leaks out, reattach adhesive tape.
         
      2. Cover the oil hole with a piece of cloth when applying air pressure to prevent oil from spraying.
         
      3. Do not lock the camshaft timing gear. If it is locked, release the lock pin again.
         

      HINT:

      1. The camshaft timing gear may be turned in the advance direction without applying any force.
         
      2. If enough air pressure cannot be applied because of air leakage from the port, releasing the lock pin may be difficult.
         

   4. Remove the adhesive tape from the No. 1 camshaft bearing cap.
      

3. Remove the flange bolt while holding the hexagonal portion of the camshaft, and then remove the camshaft timing gear.
   

   Text in Illustration 

   *a	Do Not Remove

   NOTICE:

   1. Before removing the camshaft timing gear, make sure that the lock pin has been released.
      
   2. Be sure not to remove the other 4 bolts.
      
   3. Keep the camshaft timing gear horizontal while removing it from the camshaft.
      

1. Remove the flange bolt while holding the hexagonal portion of the camshaft, and then remove the camshaft timing exhaust gear.
   

   Text in Illustration 

   *a	Do Not Remove

   NOTICE:

   1. Be sure not to remove the other 4 bolts.
      
   2. Keep the camshaft timing exhaust gear horizontal while removing it from the camshaft.
      

1. Uniformly loosen and remove the 5 bearing cap bolts in the sequence shown in the illustration.
   

2. Uniformly loosen and remove the 15 bearing cap bolts in the sequence shown in the illustration.
   

   NOTICE:

   Uniformly loosen the bolts while keeping the camshaft level.

3. Remove the 5 bearing caps.
   

   HINT:

   Arrange the removed parts in the correct order.

1. Remove the No. 2 camshaft.
   

1. Remove the camshaft.
   

1. Remove the 16 valve rocker arms.
   

   HINT:

   Arrange the removed parts in the correct order.

1. Remove the 16 valve lash adjusters from the cylinder head.
   

   HINT:

   Arrange the removed parts in the correct order.

1. Remove the 3 bolts.
   

2. Using a screwdriver with its tip wrapped with protective tape, remove the camshaft housing by prying between the cylinder head and camshaft housing.
   

   Text in Illustration 

   *1	Protective Tape

   NOTICE:

   Be careful not to damage the contact surfaces of the cylinder head and camshaft housing.

1. Using several steps, uniformly loosen and remove the 10 cylinder head bolts and 10 plate washers with a 10 mm bi-hexagon wrench in the sequence shown in the illustration.
   

   NOTICE:

   Head warpage or cracking could result from removing the bolts in the wrong order.

2. Using a screwdriver with its tip wrapped with protective tape, pry between the cylinder head and cylinder block, and remove the cylinder head.
   

   NOTICE:

   Be careful not to damage the contact surfaces of the cylinder head and cylinder block.

1. Remove the cylinder head gasket.
   

1. Remove the cylinder block water jacket spacer from the cylinder block.
   

1. Remove the oil pan drain plug and gasket from the No. 2 oil pan.
   

2. Remove the 9 bolts.
   

3. Insert the blade of the oil pan seal cutter between the oil pans as shown in the diagram. Cut through the applied sealer and remove the No. 2 oil pan.
   

   Text in Illustration 

   *1	Oil Pan Seal Cutter

   NOTICE:

   Be careful not to damage the contact surfaces of the oil pan.

1. Uniformly loosen and remove the 10 bolts.
   

2. Using a screwdriver with its tip wrapped with protective tape, remove the oil pan by prying between the oil pan and cylinder block.
   

   Text in Illustration 

   *1	Protective Tape

   NOTICE:

   Be careful not to damage the contact surfaces of the crankcase and cylinder block.

3. Remove the gasket from the cylinder block.
   

1. Remove the 6 bolts and the No. 1 oil pan baffle plate from the oil pan.
   

1. Remove the 2 bolts and the oil strainer from the oil pan.