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Part 9 Of 9:
PARTIAL ENGINE ASSY
OVERHAUL
1. REMOVE SPARK PLUG
a. Using a spark plug wrench, remove the spark plugs.
2. REMOVE THERMOSTAT
a. Remove the 2 nuts and the water inlet.
b. Remove the thermostat.
c. Remove the gasket from the thermostat.
3. REMOVE OIL FILLER CAP SUB-ASSY
a. Remove the oil filler cap from the cylinder head cover.
4. REMOVE OIL FILLER CAP GASKET
a. Using a screwdriver, remove the gasket from the oil filler cap.
5. REMOVE CRANKSHAFT POSITION SENSOR
a. Remove the bolt and the crankshaft position sensor.
6. REMOVE VENTILATION VALVE SUB-ASSY
a. Remove the ventilation valve from the cylinder head cover.
7. REMOVE CYLINDER HEAD COVER SUB-ASSY
a. Remove the 9 bolts, the 2 nuts and the cylinder head cover.
8. REMOVE CYLINDER HEAD COVER GASKET
a. Remove the gasket from the cylinder head cover.
9. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSY
a. Remove the bolt and the camshaft timing oil control valve.
10. REMOVE OIL LEVEL GAGE GUIDE
a. Remove the bolt and the oil level gage guide.
11. REMOVE WATER PUMP PULLEY
a. Using SST, hold the pump pulley.
SST 09960-10010 (09962-01000, 09963-00600)
b. Remove the 3 bolts and the pump pulley.
12. REMOVE CRANKSHAFT DAMPER SUB-ASSY
a. Set the No.1 cylinder to TDC/compression.
1. Turn the crankshaft damper, and align its timing notch with timing mark "0" of the chain cover.
2. Check that both timing marks on the camshaft timing sprocket and the camshaft timing gear are facing upward as shown in the illustration.
HINT: If not, turn the crankshaft 1 complete revolution (360°) and align the marks as above.
b. Using SST, remove the pulley bolt.
SST 09213-58012 (91111-50845), 09330-00021
HINT: If necessary, remove the damper with SST.
SST 09950-50013 (09951-05010, 09952-05010, 09953-05020, 09954-05021)
13. REMOVE ENGINE MOUNTING BRACKET RH
a. Remove the 4 bolts and the engine mounting bracket RH.
14. REMOVE WATER PUMP ASSY
a. Remove the 3 bolts and 2 nuts.
b. Remove the water pump and the gasket.
15. REMOVE OIL PUMP ASSY
a. Remove the 15 bolts and nut.
b. Using a screwdriver with the tip wrapped in tape, remove the oil pump by prying between the cylinder head and cylinder block.
NOTICE: Be careful not to damage the contact surfaces of the oil pump, the cylinder head and the cylinder block.
c. Remove the 2 O-rings from the cylinder block and the oil pan No.1.
d. Using an 8 mm hexagon wrench, remove the screw plug from the oil pump.
16. REMOVE OIL PUMP SEAL
a. Using a screwdriver with the tip wrapped in tape, remove the oil seal.
17. REMOVE CHAIN TENSIONER ASSY NO.1
NOTICE:
^ Do not rotate the crankshaft with the chain tensioner removed.
^ When rotating the camshaft with the timing chain re moved, rotate the crankshaft counterclockwise 40° from the TDC first.
a. While rotating the stopper plate of the chain tensioner upward with a screwdriver, push in the plunger of the tensioner as shown in the illustration.
b. While rotating the stopper plate of the tensioner downward, insert a 2.5 mm (0.098 inch) diameter bar into the holes of the stopper plate and the tensioner to hold the stopper plate.
c. Remove the 2 bolts and the chain tensioner.
18. REMOVE CHAIN TENSIONER SLIPPER
a. Remove the bolt and the chain tensioner slipper.
19. REMOVE CHAIN VIBRATION DAMPER NO.1
a. Remove the 2 bolts and the chain vibration damper.
20. REMOVE CHAIN SUB-ASSY
21. INSPECT CHAIN SUB-ASSY
a. Using a spring scale, pull the timing chain with 140 N (14.3 kgf, 31.5 lb) and measure the length of it.
Maximum chain elongation: 123.2 mm (4.850 inch)
If the elongation is greater than maximum, replace the chain.
HINT: Perform the same measurements by pulling at 3 or more random places to obtain the average length.
22. REMOVE FUEL DELIVERY PIPE SUB-ASSY
a. Remove the 3 bolts and the fuel delivery pipe together with the 4 fuel injectors.
23. REMOVE FUEL INJECTOR ASSY
a. Pull out the 4 injectors from the delivery pipe.
24. REMOVE CAMSHAFT POSITION SENSOR
a. Remove the bolt and the camshaft position sensor.
25. REMOVE NO.2 CAMSHAFT
NOTICE: When rotating the camshaft with the timing chain removed, rotate the crankshaft counterclockwise 40° from the TDC first, and align the oil jet hole with the paint mark. This prevents contact of the pistons with the valves.
a. Using several steps, loosen and remove the 11 bearing cap bolts uniformly in the sequence shown in the illustration, then remove the 5 bearing caps and No.2 camshaft.
NOTICE: Loosen each bolt uniformly keeping the camshaft level.