Part 1
OVERHAUL1. REMOVE OIL FILLER CAP SUB-ASSY
2. REMOVE OIL FILLER CAP GASKET
3. REMOVE VENTILATION VALVE SUB-ASSY
4. REMOVE SPARK PLUG
5. REMOVE OIL FILTER SUB-ASSY
a. Using SST, remove the oil filter.
SST 09228-06501
6. REMOVE OIL COOLER ASSY (W/ OIL COOLER)
a. Remove the flange nut.
b. Remove the union bolt and oil cooler.
c. Remove the O-ring from the oil cooler.
7. REMOVE OIL FILTER UNION (W/O OIL COOLER)
a. Using a 12 mm hexagon wrench, remove the oil filter union.
8. REMOVE CYLINDER HEAD COVER SUB-ASSY
a. Remove 8 bolts, 2 nuts, and cylinder head cover sub assembly.
9. REMOVE CYLINDER HEAD COVER GASKET
10. REMOVE CRANK POSITION SENSOR
11. REMOVE CRANKSHAFT PULLEY
a. Turn the crankshaft pulley, and align its groove with the timing mark "0" of the timing chain cover.
b. Check that the timing marks of the camshaft timing sprockets are aligned with the timing marks of the No. 1 bearing cap as shown in the illustration.
c. Using SST, fix the crankshaft pulley and loosen a pulley set bolt.
SST 09213-54015 (91651-60855), 09330-00021
d. Using a pulley set bolt and SST, remove the crankshaft pulley.
SST 09950-50013 (09951-05010, 09952-05010, 09953-05020, 09954-05021)
12. REMOVE CHAIN TENSIONER ASSY NO. 1
a. Remove the 2 nuts, timing chain tensioner and gasket.
NOTICE: Be sure not to turn the crankshaft without the chain tensioner.
13. REMOVE WATER PUMP PULLEY
a. Using SST, remove the water pump pulley.
SST 09960-10010 (09962-01000, 09963-00700)
14. REMOVE WATER PUMP ASSY
a. Remove the 4 bolts, 2 nuts, bracket and water pump.
15. REMOVE CAMSHAFT POSITION SENSOR
16. REMOVE OIL PAN DRAIN PLUG
17. REMOVE OIL PAN SUB-ASSY
a. Remove the 12 bolts and 2 nuts.
b. Insert the blade of SST between the crankcase and oil pan, cut off applied sealer and remove the oil pan.
SST 09032-00100
NOTICE: Be careful not to damage the contact surface of the cylinder block and oil pan.
18. REMOVE TIMING CHAIN COVER SUB-ASSY (TIMING CHAIN OR BELT COVER SUB-ASSY
a. Remove the 14 bolts and 2 nuts.
b. Remove the timing chain cover by prying the portions between the timing chain cover and cylinder head or cylinder block with a screwdriver.
NOTICE: Be careful not to damage the contact surfaces of the timing chain cover, cylinder block and cylinder head.
19. REMOVE TIMING CHAIN COVER OIL SEAL (TIMING GEAR CASE OIL SEAL)
a. Using a screwdriver, remove the oil seal.
20. REMOVE CRANKSHAFT POSITION SENSOR PLATE NO. 1
21. REMOVE TIMING CHAIN GUIDE
22. REMOVE CHAIN TENSIONER SLIPPER
23. REMOVE CHAIN VIBRATION DAMPER NO. 1
24. REMOVE CHAIN SUB-ASSY
25. REMOVE CRANKSHAFT TIMING GEAR OR SPROCKET
26. REMOVE NO. 2 CHAIN SUB-ASSY
a. Turn the crankshaft counterclockwise 90°, and align an adjusting hole of the oil pump drive shaft gear with the groove of the oil pump.
b. Put a bar ([diameter] 4 mm) in the adjusting hole of the oil pump drive shaft gear to lock in position, and remove a nut.
c. Remove bolt and a chain tensioner plate.
d. Remove the oil pump drive gear, oil pump drive shaft gear and No. 2 chain sub assembly.
27. REMOVE OIL PUMP ASSY
a. Remove 3 bolts and the oil pump assembly.
28. REMOVE NO. 2 CAMSHAFT
a. Remove No. 1 and No. 2 camshaft bearing caps as the sequence shown in the illustration.
b. Remove No. 2 camshaft.
29. REMOVE CAMSHAFT
a. Remove No. 1 and No. 3 camshaft bearing caps as the sequence shown in the illustration.
b. Remove No. 1 camshaft.
30. REMOVE CAMSHAFT BEARING NO. 1
31. REMOVE CAMSHAFT TIMING GEAR OR SPROCKET
a. Fix the No. 2 camshaft with a vise, and remove the camshaft timing gear.
NOTICE: Be careful not to damage the camshaft.
32. REMOVE CAMSHAFT TIMING GEAR ASSY
a. Fix the No. 1 camshaft with a vise, and make sure the camshaft timing gear assembly does not move.
b. Cover all the paths with vinyl tape except an advanced side path as shown in the illustration.
c. Put air pressure into the oil path with 150 kPa (1.5 kgf/cm2, 21 psi), and turn the camshaft timing gear assembly to the advance direction (counterclockwise) by force.
NOTICE: Cover the paths with shop rag to avoid oil splashing.
HINT: Depending on the air pressure, the VVT timing sprocket 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 form the port, there may be the case that the lock pin could be hardly released.
d. Remove a fringe bolt of camshaft timing gear assembly.
NOTICE:
- Be sure not to remove the other 4 bolts.
- In case of reusing the camshaft timing gear assembly, release the straight pin lock first, and then install the gear.
33. REMOVE CAMSHAFT BEARING NO. 2
34. REMOVE CYLINDER HEAD SUB-ASSY
a. Using a 10 mm bi-hexagon wrench, uniformly loosen and remove the 10 cylinder head bolts, in several passes, in the sequence shown. Remove the 10 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 and incorrect order.
35. REMOVE CYLINDER HEAD GASKET
36. REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSY
37. REMOVE UNION (W/ OIL COOLER)
38. REMOVE OIL CONTROL VALVE FILTER
a. Using a 6 mm socket hexagon wrench, remove a plug and oil control valve filter.
39. REMOVE W/ HEAD TAPER SCREW PLUG NO. 1
40. INSPECT BALANCE SHAFT THRUST CLEARANCE
a. Using a dial indicator, measure the thrust clearance while moving the balance shaft back and forth.
Standard thrust clearance: 0.050 - 0.090 mm (0.0020 - 0.0035 inch)
Maximum thrust clearance: 0.090 mm (0.0035 inch)