Part 1
OVERHAUL1. REMOVE SPARK PLUG
2. REMOVE OIL FILLER CAP SUB-ASSEMBLY
3. REMOVE OIL FILLER CAP GASKET
4. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH
5. REMOVE CYLINDER HEAD COVER GASKET NO.2
6. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY
7. REMOVE CYLINDER HEAD COVER GASKET
8. REMOVE VENTILATION VALVE SUB-ASSEMBLY
9. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY
10. REMOVE VVT SENSOR
a. Remove both the camshaft oil control valves.
b. Remove the O-ring from each camshaft oil control valve.
11. REMOVE OIL LEVEL GAGE SUB-ASSEMBLY
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, 09953-05020, 09954-05031)
NOTICE: Before using SST, apply lubricating oil to the threads and tip of the center bolt 150.
14. REMOVE TIMING BELT NO.1 COVER
15. REMOVE TIMING BELT NO.2 COVER
16. REMOVE ENGINE MOUNTING BRACKET RH
17. REMOVE TIMING BELT GUIDE NO.2
18. REMOVE TIMING BELT
a. Set the No. 1 cylinder to the TDC/compression.
1. Temporarily install the crankshaft pulley bolt and washer to the crankshaft.
2. Turn the crankshaft clockwise, then align the timing mark of the crankshaft timing pulley with the oil pump body.
3. Check that the timing marks of the camshaft timing pulleys and the timing belt No. 3 cover are aligned.
If not, turn the crankshaft by 1 revolution (360°).
4. Remove the crankshaft pulley bolt.
b. If reusing the timing belt, check that there are 3 installation marks on the timing belt as shown in the illustration.
1. If the installation marks have disappeared, put new installation marks on the timing belt before removing.
c. Set the No. 1 cylinder to approximately 60° BTDC/compression.
1. Turn the crankshaft counterclockwise by approximately 60°.
NOTICE: If the timing belt is disengaged, having the crankshaft pulley set at the wrong angle can cause contact of the piston head with the valve head when removing the camshaft timing pulley and camshaft, which causes damage. So always set the crankshaft pulley at the correct angle.
d. Remove the timing belt tensioner.
NOTICE: Do not reinstall the tensioner with its plunger extended.
e. Remove the timing belt in this order.
19. REMOVE TIMING BELT IDLER SUB-ASSEMBLY NO.1
a. Using a socket hexagon wrench 10, remove the pivot bolt, timing belt idler No. 1 and plate washer.
20. REMOVE TIMING BELT IDLER SUB-ASSEMBLY NO.2
21. REMOVE CRANKSHAFT 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.
SST 09960-10010 (09962-01000, 09963-01000)
HINT: Arrange the camshaft timing pulleys (RH and LH sides) so that they can be returned to the original locations when reassembling.
23. REMOVE TIMING BELT NO.3 COVER
24. REMOVE TIMING BELT IDLER BRACKET
25. REMOVE CRANKSHAFT TIMING PULLEY
a. Remove the bolt and timing belt plate.
b. Install the pulley bolt to the crankshaft.
c. Using SST remove the crankshaft timing pulley.
SST 09950-50013 (09951-05010, 09952-05010, 09953-05020, 09954-05011)
NOTICE:
^ Do not scratch the sensor part of the crankshaft timing pulley.
^ Before using SST, apply lubricating oil to the threads and tip of the center bolt 150.
26. REMOVE WATER PUMP ASSEMBLY
a. Remove the 3 bolts and 3 nuts, then remove the water pump and gasket.
27. REMOVE CAMSHAFT
NOTICE: Since the thrust clearance of the camshaft is small, the camshaft must be kept level while being removed. If the camshaft is not kept level, the cylinder head or camshaft may be damaged. To avoid this, the following steps must 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 installation of the service bolt.
c. Using several steps, loosen and remove the 10 bearing cap bolts uniformly in the sequence shown in the illustration. Remove the 5 bearing caps and camshaft.
NOTICE:
^ Do not pry out the camshaft.
^ Be careful not to damage the contact surface of the cylinder head that receives the shaft thrust.
28. REMOVE NO.2 CAMSHAFT
a. Using several steps, loosen and remove the 10 bearing cap bolts uniformly in the sequence shown in the illustration. Remove the 5 bearing caps and No. 2 camshaft.
NOTICE:
^ Do not pry out the camshaft.
^ Be careful not to damage the contact surface of the cylinder head that receives the shaft thrust.
b. Remove the oil seal from the No. 2 camshaft.
29. REMOVE NO.3 CAMSHAFT SUB-ASSEMBLY
NOTICE: Since the thrust clearance of the camshaft is small, the camshaft must be kept level while being removed. If the camshaft is not kept level, the cylinder head or camshaft may be damaged. To avoid this, the following steps must be carried out.
a. Align the timing marks (1 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 installation of the service bolt.
c. Using several steps, loosen and remove the 10 bearing cap bolts uniformly in the sequence shown in the illustration. Remove the 5 bearing caps and No. 3 camshaft.
NOTICE:
^ Do not pry out the camshaft.
^ Be careful not to damage the contact surface of the cylinder head that receives the shaft thrust.
30. REMOVE NO.1 CAMSHAFT SUB-ASSEMBLY
a. Using several steps, loosen and remove the 10 bearing cap bolts uniformly in the sequence shown in the illustration. Remove the 5 bearing caps and No. 4 camshaft.
NOTICE:
^ Do not pry out the camshaft.
^ Be careful not to damage the contact surface of the cylinder head that receives the shaft thrust.
b. Remove the oil seal from the No. 4 camshaft.
31. INSPECT CAMSHAFT TIMING GEAR ASSEMBLY
a. Clamp the camshaft in a vise on the hexagonal lobe.
b. Check that the VVT-i will not turn.
c. Cover all the oil ports with vinyl tape except the port on the advance angle side (nearest to the convex portion) shown in the illustration.
d. Using the air gun, apply about 100 kPa (1 kgf/cm2, 14 psi) of air pressure to the port on the advance angle side.
NOTICE: Some oil spraying will occur. Be prepared to catch the spray with a shop rag.
HINT: This operation releases the lock pin for the most retard angle lock.
e. Under the condition above, turn the VVT-i to the advance angle side (the direction of the white arrow in the illustration) by hand.
Standard: Must turn
HINT: Depending on the air pressure, the VVT-i will turn to the advance angle side without applying force by hand. Also, if the pressure can be hardly applied because of the air leakage from the port, the lock pin might not be released easily.
f. Check that the VVT-i moves freely within about 30° range. Avoid moving the VVT-i unit to the most retard angle position as the lock pin will engage again. Standard: Smooth movable range is about 30°.
g. Turn the VVT-i by hand, then lock it at the most retard angle position.
32. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY
NOTICE: Do not remove or install the camshaft timing gear (VVT-i) unless you are replacing the VVT-i or camshaft.
a. Clamp the camshaft in a vise on the hexagonal lobe.
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 with the lock pin engaged and locked at the most retard angle position.
^ The lock nut has LH threads.
^ Never use any tools other than the socket wrench. Other tools will deform the cam angle rotor.
c. Remove the camshaft VVT-i.
NOTICE: Never remove the 3 bolts on the gear.
If it is difficult to remove VVT-i, tap it lightly using a plastic-faced hammer, then remove it.
33. REMOVE CAMSHAFT SUB GEAR
a. Clamp the camshaft in a vise on the hexagonal lobe.
NOTICE: Be careful not to damage the camshaft.
b. Using SST, turn the sub gear counterclockwise, then re move 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 cam shaft gear bolt washer.
HINT: Arrange the camshaft sub gears and gear bolt washers (RH and LH sides) so that they can be returned to the original locations when reassembling.