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Part 6 Of 6:

OVERHAUL
1. 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 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, 09963-01000)

b. Using SST, remove the bolt and LH timing pulley.

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 09950-50013 (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 above 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 camshaft.

NOTICE:
^ 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-gear has been eliminated by the above 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 above, 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).

35. REMOVE ENGINE HANGER NO.2
36. REMOVE CYLINDER HEAD COVER REAR

37. REMOVE OIL CONTROL VALVE FILTER
a. Remove the plug, gasket and valve filter.
38. REMOVE CYLINDER HEAD SUB-ASSY

a. Using an 8 mm hexagon wrench, remove the hexagon bolt.

b. Uniformly loosen the 8 cylinder head bolts, in several passes, in the sequence shown. Remove the 8 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.

39. REMOVE CYLINDER HEAD GASKET
40. REMOVE CYLINDER HEAD LH

a. Using an 8 mm hexagon wrench, remove the hexagon bolt.

42. REMOVE WATER INLET HOUSING
a. Remove the 8 bolts, 2 nuts and water inlet housing.

43. REMOVE OIL FILTER SUB-ASSY
a. Using SST, remove the oil filter.
SST 09228-07501
b. Using a 12 mm socket hexagon wrench, remove the oil filter union.
44. REMOVE CYLINDER BLOCK SIDE COVER DRAIN COCK PLUG
45. REMOVE CYLINDER BLOCK SIDE COVER
46. REMOVE OIL PAN DRAIN PLUG

47. REMOVE OIL PAN SUB-ASSY NO.2
a. Remove the 10 bolts and 2 nuts.
b. Insert the blade of SST between No. 1 oil pan and No. 2 oil pan, and cut off applied sealer and remove the No. 2 oil pan.
SST 09032-00100

NOTICE: Be careful not to damage the No. 2 oil pan contact surface of the No. 1 oil pan and the No. 2 oil pan flange.

48. REMOVE OIL STRAINER SUB-ASSY
a. Remove the bolt, 2 nuts, oil strainer and gasket.
49. REMOVE OIL PAN SUB-ASSY

a. Uniformly loosen and remove the 15 bolts and 2 nuts.

b. Using screwdriver, remove the No. 1 oil pan by prying the portions between the cylinder block and No. 1 oil pan.

NOTICE: Be careful not to damage the contact surfaces of the No. 1 oil pan and cylinder block.

50. REMOVE OIL PAN BAFFLE PLATE

51. REMOVE ENGINE REAR OIL SEAL RETAINER
a. Remove the 6 bolts.
b. Using a screwdriver, remove the oil seal retainer by prying the portions between the oil seal retainer and main bearing cap.

52. REMOVE ENGINE REAR OIL SEAL
a. Using a screwdriver and a hammer, tap out the oil seal.

53. REMOVE OIL PUMP ASSY
a. Remove the 9 bolts.
b. Remove the oil pump by prying a screwdriver between the oil pump and main bearing cap.
c. Remove the O-ring.

54. REMOVE OIL PUMP SEAL
a. Using a screwdriver, pry out the oil seal.
55. REMOVE SPARK PLUG TUBE GASKET

a. Bend up the tab on the ventilation baffle plate which prevents the gasket from the slipping out.

NOTICE: Be careful not to damage the baffle plate of the cylinder head cover.

b. Using a screwdriver and a hammer, tap out the gasket.

c. Using needle-nose pliers, pry out the gasket.

NOTICE: Be careful not to damage the cylinder head cover.

56. INSPECT TIMING BELT

NOTICE:
^ Do not bend, twist or turn the timing belt inside out.
^ Do not allow the timing belt to come into contact with oil, water or steam.
^ Do not utilize timing belt tension when installing or re moving the mount bolt of the camshaft timing pulley.

If there are any defects, as shown in the illustrations, check these points below.
a. If there is premature parting,
^ Check for proper installation.
^ Check the timing cover gasket for damage and proper installation.
b. If the belt teeth are cracked or damaged, check to see if either camshaft is locked.
c. If there is noticeable wear or cracks on the belt face, check to see if there are nicks on the side of the idler pulley lock and water pump.
d. If there is wear or damage on only one side of the belt, check the belt guide and the alignment of each pulley.
e. If there is noticeable wear on the belt teeth,
^ Check timing cover for damage.
^ Check gasket has been installed correctly.
^ Check for foreign material on the pulley teeth.
If necessary, replace the timing belt.
57. INSPECT CAMSHAFT

a. Inspect camshaft for runout.
1) Place the camshaft on V-blocks.
2) Using a dial indicator, measure the circle runout at the center journal.
Maximum circle runout: 0.06 mm (0.0024 inch)
If the circle runout is greater than maximum, replace the camshaft.

b. Inspect cam lobes.
1) Using a micrometer, measure the cam lobe height.
Standard cam lobe height:
Intake 42.932 - 43.032 mm (1.6902 - 1.6942 inch)
Exhaust 42.764 - 42.864 mm (1.6836 - 1.6876 inch)
Minimum cam lobe height:
Intake 42.78 mm (1.6842 inch)
Exhaust 42.61 mm (1.6776 inch)
If the cam lobe height is less than minimum, replace the camshaft.

c. Inspect camshaft journals.
1) Using a micrometer, measure the journal diameter.
Journal diameter: 26.959 - 26.975 mm (1.0614 - 1.0620 inch)
If the journal diameter is not as specified, check the oil clearance.

58. INSPECT CYLINDER HEAD SET BOLT
a. Using vernier calipers, measure the tension portion diameter of the bolt.
Standard outside diameter: 8.95 - 9.05 mm (0.3524 - 0.3563 inch)
Minimum outside diameter: 8.75 mm (0.3775 inch)
If the diameter is less than minimum, replace the bolt.
59. INSTALL SPARK PLUG TUBE GASKET

a. Using SST and a hammer, tap in a new gasket until its surface is flush with the upper edge of the cylinder head cover.
SST 09950-60010 (09951-00430), 09950-70010 (09951-07100)
b. Return the ventilation plate tab to its original position.
c. Apply a light coat of MP grease to the gasket lip.
60. INSTALL ENGINE REAR OIL SEAL

a. Using SST and a hammer, tap in a new oil seal until its surface is flush with the rear oil seal retainer edge.
SST 09223-15030, 09950-70010 (09951-07100)

NOTICE:
^ Be careful not to tap the oil seal slantingly.
^ Keep the lip off foreign materials.

b. Apply MP grease to the oil seal lip.

61. INSTALL ENGINE REAR OIL SEAL RETAINER
a. Remove any old packing material from the contact surface.
b. Apply seal packing in the shape of bead (Diameter 2 - 3 mm (0.08 - 0.12 inch)) consequently as shown in the illustration.
Seal packing: Part No. 08826-00080 or equivalent

NOTICE:
^ Remove any oil from the contact surface.
^ Install the oil seal retainer within 3 minutes after applying seal packing.
^ Do not put into engine oil within 2 hours after installing.

c. Install the oil seal retainer with the 6 bolts, uniformly tighten the bolt in several passes.
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)
62. INSTALL OIL PUMP SEAL

a. Using SST and a hammer, tap in a new oil seal until its surface is flush with the oil pump body edge.
SST 09223-00010

NOTICE:
^ Be careful not to tap the oil seal slantingly.
^ Keep the lip off foreign materials.

b. Apply MP grease to the oil seal lip.
63. INSTALL OIL PUMP ASSY

a. Remove any old packing material from the contact surface.
b. Apply a light coat of engine oil to a new O-ring and place it on the cylinder block.

c. Apply seal packing in the shape of bead (Diameter 2 - 3 mm (0.08 - 0.12 inch)) consequently as shown in the illustration.
Seal packing: Part No. 08826-00080 or equivalent

NOTICE:
^ Apply seal packing to the inner side of the bolt hole. Remove any oil from contact surface.
^ Install the oil pump within 3 minutes after applying seal packing.
^ Do not put into engine oil within 2 hours after installing.

d. Engage the spline teeth of the oil pump drive gear with the large teeth of the crankshaft, and slide the oil pump on the crankshaft.
e. Install the oil pump with the 9 bolts. Uniformly tighten the bolts in several passes.
Torque:
10 mm head 8.0 Nm (82 kgf-cm, 71 inch lbs.)
12 mm head 20 Nm (199 kgf-cm, 14 ft. lbs.)
14 mm head 43 Nm (439 kgf-cm, 32 ft. lbs.)
64. INSTALL CRANK POSITION SENSOR
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)
65. INSTALL OIL PAN BAFFLE PLATE
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)

66. INSTALL OIL PAN SUB-ASSY
a. Remove any old packing material from the contact surface.
b. Apply seal packing in the shape of bead (Diameter 3 - 4 mm (0.12 - 0.16 inch)) consequently as shown in the illustration.
Seal packing: Part No. 08826-00080 or equivalent

NOTICE:
^ Apply seal packing to the outer side of the bolt hole in the region "X".
^ Apply seal packing to the inner side of the bolt hole in the region "Y".
^ Remove any oil from the contact surface.
^ Install the No.1 oil pan within 3 minutes after applying seal packing.
^ Do not put into engine oil within 2 hours after installing.
^ Install the No.1 oil pan with the 15 bolts and 2 nuts. Uniformly tighten the bolts in several passes.

Torque:
10 mm head 8.0 Nm (82 kgf-cm, 71 inch lbs.)
12 mm head 20 Nm (199 kgf-cm, 14 ft. lbs.)
67. INSTALL OIL STRAINER SUB-ASSY
a. Install a new gasket and the oil strainer with the bolt and 2 nuts.
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)

68. INSTALL OIL PAN SUB-ASSY NO.2
a. Remove any old packing material from the contact surface.
b. Apply seal packing in the shape of bead (Diameter 4 - 5 mm (0.16 - 0.20 inch)) consequently as shown in the illustration.

Seal packing: Part No. 08826-00080 or equivalent

NOTICE:
^ Remove any oil from the contact surface.
^ Apply seal packing to the inner side of the bolt hole.
^ Install the oil pan within 3 minutes after applying seal packing.
^ Do not put into engine oil within 2 hours after installing.

c. Install the No. 2 oil pan with the 10 bolts and 2 nuts.
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)
69. INSTALL OIL PAN DRAIN PLUG
a. Install the drain plug with a new gasket.
Torque: 45 Nm(459 kgf-cm, 33 ft. lbs.)
70. INSTALL CYLINDER BLOCK SIDE COVER
a. Install a new gasket and the cylinder block side cover with the 3 bolts and 2 nuts.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)