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OVERHAUL

26. REMOVE CRANKSHAFT TIMING PULLEY
a. Install the pulley bolt to the crankshaft.
b. Using SST, remove the crankshaft timing pulley.
SST 09950-50012 (09951-05010, 09952-05010, 0995-05020, 09950-05010)

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 in level while it is being removed. If the camshaft is not kept in 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.

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 by 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.

If it is difficult 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 (2WD DRIVE TYPE)
45. REMOVE CYLINDER BLOCK SIDE COVER (2WD DRIVE TYPE)
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