Part 1 of 2
Removal
CAUTION:
- Use fender covers to avoid damaging painted surfaces.
- To avoid damage, unplug the wiring connectors carefully while holding the connector portion.
NOTE:
- Mark all wiring and hoses to avoid misconnection.
- Turn the crankshaft pulley so that the No.1 piston is at top dead center.
1. Disconnect the battery negative cable.
2. Loosen the drain plug and drain the engine coolant.
3. Remove the intake air hose and air cleaner assembly.
4. Remove the radiator upper hose (A) and lower hose (B).
5. Disconnect the fuel hose (A).
6. Disconnect the brake booster vacuum hose (B).
7. Remove the cooling fan.
8. Disconnect the engine wiring harness connectors and hoses.
(1) RH knock sensor connector (A)
(2) Power steering switch connector (B)
(3) PCSV connector (A)
(4) ETC connector (A)
(5) MAP sensor connector (B)
(6) RH exhaust camshaft oil control valve (OCV) connector (C)
(7) RH ignition connector (D)
(8) RH injector connector (E)
(9) LH exhaust camshaft oil control valve (OCV) connector (A)
(10) Oil pressure connector (B)
(11) LH injector connector (C)
(12) LH/RH intake camshaft oil control valve connector (D)
(13) Ignition coil condenser connector (E)
(14) Greenbug line (F)
(15) LH ignition coil connector (A)
(16) Fuel pressure control valve (B)
(17) LH intake camshaft position sensor (CMPS) connector (A)
(18) LH exhaust camshaft position sensor (CMPS) connector (B)
(19) LH front oxygen sensor connector (C)
(20) Crankshaft position sensor connector
(21) LH knock sensor connector
(22) Water temperature sensor connector (A)
(23) RH intake camshaft position sensor (CMPS) connector (B)
(24) RH exhaust camshaft position sensor (CMPS) connector (C)
(25) Oil temperature sensor connector (D)
(26) RH front oxygen sensor connector (E)
(27) Ignition coil condenser connector (F)
(28) PCSV hose (A), PCV hose (B)
(29) Throttle body water hose (C)
9. Remove the surge tank assembly (A).
10. Remove the breather pipe & hose (A).
11. Disconnect the water hose & pipe (A) and then remove the intake manifold (B).
CAUTION:
- Be sure to drain the engine coolant before removing the intake manifold.
- If any coolant drained from the cylinder head vent hole has entered the intake port. This can potentially lead to engine trouble.
12. Remove the high pressure fuel pipe.
13. Remove the RH ignition coils (A) and the wiring.
14. Remove the LH ignition coils (A) and the wiring.
15. Remove the fuel pump (B) and the roller tappet (C).
16. Remove the LH cylinder head cover (B) after remove the OCV cap (A).
17. Disconnect the water outlet pipe (A).
18. Remove the RH cylinder head cover (C) after remove the OCV cap (B).
NOTE:
Cover the cylinder head with a clean woven stuff or vinyl cover to prevent foreign materials from entering.
19. Drain the engine oil.
20. Remove the lower oil pan (A).
Insert the blade of SST(09215-3C000) between the upper oil pan and lower oil pan. Cut off applied sealer and remove the lower oil pan.
NOTE:
- Insert the SST between the oil pan and the ladder frame by tapping it with a plastic hammer in the direction of arrow.
- After tapping the SST with a plastic hammer along the direction of arrow around more than 2/3 edge of the oil pan, remove it from the ladder frame.
- Do not turn over the SST abruptly without tapping. It be result in damage of the SST.
- Be careful not to damage the contact surfaces of Upper oil pan and lower oil pan.
21. Remove the drive belt (B) after removing the oil level gauge (A).
22. Remove the air conditioner compressor (A).
23. Remove the alternator (A).
24. Remove the oil filter body (A).
25. Remove the water pump pulley (A).
26. Remove the drive belt idler (A).
27. Remove the drive belt auto tensioner (A).
28. Set No.1 cylinder to TDC/compression.
(1) Turn the crankshaft pulley clockwise and align its groove with the timing mark "T" of the lower timing chain cover.
(2) Check that the mark of the camshaft timing sprockets are in straight line on the cylinder head surface as shown in the illustration. If not, turn the crankshaft clockwise one revolution (360°).
NOTE:
Do not rotate engine counterclockwise.
29. Remove the crankshaft pulley (A).
NOTE:
Use the SST(09231-2J210, 09231-2J200) fix the crankshaft pulley.
30. Remove the water pump (A) and the gaskets (B).
31. Remove the timing chain cover (A).
CAUTION:
Be careful not to damage the contact surfaces of cylinder block, cylinder head and timing chain cover.
NOTE:
Before removing the timing chain, mark the RH/LH timing chain with an identification based on the location of the sprocket because the identification mark on the chain for TDC (Top Dead Center) can be erased.
32. Remove the oil pump chain cover (A).
33. Remove the oil pump chain tensioner assembly (A).
34. Release the ratchet using a thin rod.
Compress the piston and then insert a stopper pin into the hole on the ratchet to hold the compressed piston.
35. Remove the RH timing chain cam to cam guide (A).
36. Remove the RH timing chain auto tensioner (A) and the RH timing chain tensioner arm (B).
37. Remove the RH timing chain guide (A).
38. Remove the RH timing chain (A).
39. Remove the crankshaft RH timing chain sprocket (A).
40. Remove the oil pump chain sprocket (A) and oil pump chain (B).
41. Remove the crankshaft oil pump chain sprocket (A).
42. Release the ratchet using a thin rod.
Compress the piston and then insert a stopper pin into the hole on the ratchet to hold the compressed piston.
43. Remove the LH timing chain cam to cam guide (A).
44. Remove the LH timing chain auto tensioner (A) and LH timing chain tensioner arm (B).
45. Remove the LH timing chain guide (A).
46. Remove the timing chain (A).
47. Remove the crankshaft LH timing chain sprocket (A).
48. Remove the tensioner adapter assembly (A).
Inspection
Sprockets, Chain Tensioner, Chain Guide, Chain Tensioner Arm
1. Check the camshaft sprocket and crankshaft sprocket for abnormal wear, cracks, or damage. Replace as necessary.
2. Inspect the tensioner arm and chain guide for abnormal wear, cracks, or damage. Replace as necessary.
3. Check that the tensioner piston moves smoothly when the ratchet pawl is released with thin rod.