Part 1
OVERHAUL1. 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
a. Remove the 2 camshaft oil control valves.
b. Remove the O-ring from each camshaft oil control valve.
10. REMOVE CRANK POSITION SENSOR NO.1
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, 09953-05010, 09954-05030)
NOTICE: Before using SST, apply lubricating oil on the threads and tip of the center bolt 100.
14. REMOVE TIMING BELT NO.1 COVER
15. REMOVE TIMING BELT NO.2 COVER
16. REMOVE TRANSVERSE ENGINE ENGINE MOUNTING BRACKET
17. REMOVE TIMING BELT GUIDE NO.2
18. REMOVE TIMING BELT
a. Set No. 1 cylinder to TDC/compression.
1. Temporarily install the crankshaft pulley bolt with the washer to the crankshaft.
2. Turn the crankshaft clockwise, and align the timing marks of the crankshaft timing pulley and 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. Place 3 installation marks and front mark on the timing belt.
HINT: It is not necessary if the marks are still existed.
1. Place 3 new installation marks on the timing belt to match the timing marks of the timing pulleys.
2. Place a new front mark on the timing belt.
c. Remove the timing belt tensioner.
NOTICE: Do not install the tensioner as it removed.
d. Remove the timing belt in this order.
19. REMOVE TIMING BELT IDLER SUB-ASSY NO.1
a. Using a 10 mm hexagon wrench, remove the bolt idler pulley and plate washer.
20. REMOVE TIMING BELT IDLER SUB-ASSY NO.2
21. REMOVE CRANK POSITION SENSOR
22. REMOVE CAMSHAFT TIMING PULLEY
a. Using SST, remove the bolt and RH timing pulley.
SST 09960-10010 (09962-01000, 0996-01000)
b. Using SST, remove the bolt and LH timing pulley.
SST 09960-10010 (09962-01000, 0996-01000)
HINT: Arrange the camshaft timing pulleys (RH and LH sides).
23. REMOVE TIMING BELT NO.3 COVER
24. REMOVE TIMING BELT IDLER BRACKET
25. REMOVE TIMING BELT PLATE
26. REMOVE CRANKSHAFT TIMING PULLEY
a. Install the pulley bolt to the crankshaft
b. Using SST, remove the crankshaft timing pulley.
SST 0995-50013 (09951-05010, 09952-05010, 09953-05020, 09954-05010)
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.
27. REMOVE WATER PUMP ASSY
a. Remove the 4 bolts, 2 nuts, water pump and gasket.
28. REMOVE CAMSHAFT
NOTICE: Since the thrust clearance of the camshaft is small, the camshaft must be held level while it is being removed. If the camshaft is not kept level, the portion of the cylinder head receiving the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, the following steps should be carried out.
a. Align the timing marks (2 dot marks) of the camshaft drive and driven gears by turning the camshaft with a wrench.
b. Secure the exhaust camshaft sub-gear to the main gear with a service bolt
Torque: 5.4 Nm (55 kgf-cm, 48 inch lbs.)
Recommended service bolt
HINT: When removing the camshaft, make certain that the torsional spring force of the sub-gear has been eliminated by the operation
c. Uniformly loosen and remove the 10 bearing cap bolts, in
NOTICE: several passes, in the sequence shown, and remove the 5 bearing caps and camshaft. Do not pry out the camshaft. Be careful no to damage the portion of the cylinder head receiving the shaft thrust.
29. REMOVE NO.2 CAMSHAFT
a. Uniformly loosen and remove the 10 bearing cap bolts, in several passes, in the sequence shown, and remove the 5 bearing caps and 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
30. REMOVE NO.3 CAMSHAFT SUB-ASSY
NOTICE: Since the thrust clearance of the camshaft is small, the camshaft must be held level while it is being removed. If the camshaft is not kept level, the portion of the cylinder head receiving the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, the following steps should be carried out.
a. Align the timing marks (2 dot marks) of the camshaft drive and driven gears by turning the camshaft with a wrench.
b. Secure the exhaust camshaft sub-gear to the main gear with a service bolt.
Torque: 5.4 Nm (55 kgf-cm, 48 inch lbs.)
Recommended service bolt
HINT: When removing the camshaft, make certain that the torsional spring force of the sub-ear has been eliminated by the operation.
c. Uniformly loosen and remove the 10 bearing cap bolts, in several passes, in the sequence shown, and remove the 5 bearing caps and 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.
31. REMOVE NO.4 CAMSHAFT SUB-ASSY
a. Uniformly loosen and remove the 10 bearing cap bolts, in several passes, in the sequence shown, and remove the 5 bearing caps and 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.
32. INSPECT CAMSHAFT TIMING GEAR ASSY
a. Fix the hexagon wrench head portion of the camshaft in a vise.
b. Check that VVT-i will not turn.
c. Cover the port except the port on the advance angle side (nearest to the convex portion) shown in the illustration with the vinyl tape.
d. Using the air gun, apply about 100 kPa (1 kgf/cm2, 14 psi) of air pressure to the port on the advance side shown in the illustration.
NOTICE: When the oil is splashed, wipe it off with a shop rag.
HINT: Perform this in order to release the lock pin for the maximum delay angle locking.
e. Under the condition, turn VVT-i to the advance angle side (the white arrow marked direction in the illustration) with hand.
Standard: Must turn
HINT: Depending on the air pressure, VVT-i will turn to the advance angle side without applying force by hand. Also, under the condition that the pressure can be hardly applied because of the air leakage from the port, there may be the case that the lock pin could be hardly released.
f. Except the portion where the lock pin meets at the maximum delay angle, let VVT-i turn back and forth and check the movable range and that there is no disturbance.
Standard: Movable smoothly in the range about 30°
g. Turn VVT-i your hand and lock it at the maximum delay angel position.
33. REMOVE CAMSHAFT TIMING GEAR ASSY
NOTICE: Do not remove or install the camshaft timing gear (VVT-i) beside changing VVT-i or the camshaft.
a. Fix the hexagon wrench head portion of the camshaft in a vise.
NOTICE: Be careful not to damage the camshaft.
b. Using a 46 mm socket wrench, remove the lock nut by turning it clockwise.
NOTICE:
- Remove it under the condition that the lock pin is operated and locked at the maximum delay angle position.
- The lock nut has LH threads.
- Never use any tool other than the socket wrench, otherwise that may result in deforming the cam angle rotor portion.
c. Remove the camshaft VVT-i.
NOTICE: Never remove the 3 bolts on the gear.
HINT: In case of having difficulty to remove VVT-i, apply a slight hitting using a plastic-faced hammer and then remove it.
34. REMOVE CAMSHAFT SUB GEAR
a. Fix the hexagonal wrench head portion of the camshaft in a vise.
NOTICE: Be careful not to damage the camshaft.
b. Using SST, turn the sub-gear counterclockwise, and remove the service bolt.
SST 09960-10010 (09962-01000, 09963-00500)
c. Using snap ring pliers, remove the snap ring.
d. Remove the wave washer, camshaft sub-gear and camshaft gear spring.
HINT: Arrange the camshaft sub-gears and gear springs (RH and LH sides).