Part 1

OVERHAUL
1. REMOVE OIL FILLER CAP SUB-ASSEMBLY
2. REMOVE OIL FILLER CAP GASKET





a) Using a screwdriver, remove the gasket from the oil filler cap.
3. REMOVE VENTILATION VALVE SUB-ASSEMBLY
4. REMOVE SPARK PLUG
a) Using a spark plug wrench, remove the 4 spark plugs.
5. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY





a) Remove the 9 bolts, then remove the cylinder head cover.
b) Remove the 4 spark plug tube gaskets and O-rings.
6. REMOVE CYLINDER HEAD COVER GASKET
a) Remove the cylinder head cover gasket from the cylinder head cover.
7. REMOVE WATER PUMP PULLEY





a) Using SST, remove the water pump pulley.
SST 09960-10010 (09962-01000, 09963-00600)
8. REMOVE WATER PUMP ASSEMBLY





a) Remove the 6 bolts, then remove the water pump.
b) Remove the O-ring from the timing chain cover.
9. REMOVE TRANSVERSE ENGINE ENGINE MOUNTING BRACKET





a) Remove the 4 bolts, then remove the engine mounting bracket.
10. SET NO. 1 CYLINDER TO TDC/COMPRESSION





a) Turn the crankshaft pulley until its groove and the timing chain cover are aligned.
b) Check that the point marks of the camshaft timing sprocket and the VVT timing sprocket are as shown in the illustration.

HINT: If not, turn the crankshaft 1 revolution (360°) so as to align the marks as above.

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 ASSEMBLY NO. 1





a) Remove the 2 nuts, then remove the chain tensioner assembly No. 1.

NOTICE: Do not to turn the crankshaft without the chain tensioner.

13. REMOVE TIMING CHAIN OR BELT COVER SUB-ASSEMBLY





a) Remove the 13 bolts and timing chain cover.
b) Remove the 2 gaskets from the timing chain cover.

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

14. REMOVE TIMING CHAIN OR BELT COVER OIL SEAL





a) Place the timing chain cover on a wooden block.
b) Using a screwdriver, remove the timing chain cover oil seal.
15. REMOVE CRANKSHAFT POSITION SENSOR PLATE NO. 1
16. REMOVE CHAIN TENSIONER SLIPPER
a) Remove the bolt, then remove the chain tensioner slipper.
17. REMOVE CHAIN VIBRATION DAMPER NO. 1
a) Remove the 2 bolts, then remove the chain vibration damper No. 1.
18. REMOVE CHAIN SUB-ASSEMBLY





a) Using 2 screwdrivers, pry out the chain together with the crankshaft timing gear, as shown in the illustration.

NOTICE:
^ Use a shop rag to protect the engine.
^ If revolving the camshafts with the chain off the gears, turn the crankshaft 1/4 revolution to prevent the valves from coming into contact with the pistons.

19. REMOVE OIL PUMP ASSEMBLY





a) Remove the 5 bolts, then remove the oil pump.
b) Remove the gasket from the cylinder block.
20. REMOVE CAMSHAFT





a) Using several steps, uniformly loosen and remove the 20 bolts in the sequence shown in the illustration.
b) Remove the 2 camshafts from the cylinder head.
21. REMOVE CAMSHAFT TIMING GEAR OR SPROCKET





a) Clamp the No. 2 camshaft in a vise, then remove the camshaft timing gear.

NOTICE: Be careful not to damage the camshaft.

22. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY
a) Check the lock of camshaft timing gear.





1) Clamp the camshaft in a vise, then confirm that the camshaft timing gear is locked.

NOTICE: Be careful not to damage the camshaft.

b) Check that the camshaft timing gear assembly does not rotate.

NOTICE: Do not damage the camshaft by clamping it in a vise too tightly.

c) Cover the 4 oil paths of the cam journal with vinyl tape as shown in the illustration.

HINT: One of the 2 grooves located on the cam journal is for retarding cam timing (upper) and the other is for advancing cam timing (lower). Each groove has 2 oil paths. Plug one of the 2 oil paths for each groove with a piece of rubber before wrapping the cam journal with the tape.

d) Puncture the tape over the advance side path and retard side path on the opposite side of the groove.





e) Apply approximately 150 kPa (1.5 kgf/cm2) of air pressure to the retard side oil path.

NOTICE: When applying air pressure, cover the paths with a shop rag to prevent oil splashes.

f) Apply approximately 150 kPa (1.5 kgf/cm2) of air pressure to the advance side oil path.





g) Confirm that the camshaft timing gear assembly revolves in the advance direction when reducing the air pressure of the retard side path.

HINT:
^ If the timing gear assembly does not revolve in the advance direction by air pressure, turn it forcibly by hand after air pressure is applied to both oil paths. When revolving, first turn it in the retard direction, then in the advance direction.
^ The lock pin is released, and the camshaft timing gear revolves in the advance direction.

h) When the camshaft timing gear assembly comes to the most advanced position, release the air pressure of the retard side path, then release the air pressure of the advance side path.

NOTICE: If the air pressure of the advance side path is released first, the camshaft timing gear assembly occasionally shifts abruptly in the retard direction. This may cause breakage of the lock pin. Be sure to release the air pressure on the retard side path first.





i) Remove the bolt and camshaft timing gear assembly.

NOTICE:
^ Do not remove the other 4 bolts.
^ When reusing the camshaft timing gear assembly, unlock the lock pin inside the camshaft timing gear first.

23. REMOVE CAM TIMING CONTROL VALVE HOUSING





a) Remove the 3 bolts and 2 nuts, then remove the cam timing control valve housing.
b) Remove the gasket.
24. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY