Part 1

OVERHAUL

HINT:
^ Thoroughly clean all parts to be assembled.
^ Before installing the parts, apply new engine oil to all sliding and rotating surfaces.
^ Replace all gaskets, O-rings and oil seals with new ones.





1. REMOVE ENGINE HANGER NO.1
a. Remove the 2 bolts and engine hanger No.1.
2. REMOVE ENGINE HANGER NO.2
a. Remove the 2 bolts and engine hanger No.2.
3. REMOVE OIL LEVEL GAUGE GUIDE
a. Remove the bolt and pull out the oil level gauge guide.
b. Remove the O-ring from the oil level gauge guide.
4. REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY
a. Remove the 2 water drain cocks.
5. REMOVE VVT SENSOR
a. Remove the 2 bolts and 2 VVT sensors.
6. REMOVE CRANKSHAFT POSITION SENSOR
a. Remove the bolt and crankshaft position sensor.





7. REMOVE OIL CONTROL VALVE FILTER
a. Remove the plug, filter and gasket from each cylinder head.





8. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY
a. Remove the 10 bolts, 3 seal washers, 2 nuts, cylinder head cover and gasket.





9. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH
a. Remove the 10 bolts, 3 seal washers, 2 nuts, cylinder head cover and gasket.
b. Remove the ventilation valve from the cylinder head cover.
10. REMOVE CRANKSHAFT PULLEY





a. Turn the crankshaft pulley, and align the notch with the timing mark "0" of the timing chain cover.





b. Check that the timing marks of the camshaft timing gears are aligned with the timing marks of the bearing caps as shown in the illustration.





c. Using SST, hold the crankshaft pulley and loosen the pulley set bolt.
SST 09213-54015 (91651-60855), 09330-00021





d. Using the pulley set bolt and SST, remove the crankshaft pulley.
SST 09950-50013 (09951-05010, 09952-05010, 09953-05020, 09954-05030)
11. REMOVE OIL PAN DRAIN PLUG
a. Remove the drain plug and gasket.
12. REMOVE OIL PAN SUB-ASSEMBLY NO.2





a. Remove the 10 bolts and 2 nuts.





b. Insert the blade of SST between the oil pan and oil pan No.2, and cut off applied sealer and remove the oil pan No.2.
SST 09032-00100

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

13. REMOVE OIL STRAINER SUB-ASSEMBLY





a. Remove the 2 nuts, oil strainer and gasket.
14. REMOVE OIL PAN SUB-ASSEMBLY





a. Remove the 17 bolts and 2 nuts.
b. Remove the 4 stud bolts.





c. Using a screwdriver, remove the oil pan by prying between the oil pan and cylinder block as shown in the illustration.

NOTICE: Be careful not to damage the contact surfaces of the cylinder block and oil pan.

d. Remove the O-ring from the oil pump.





15. REMOVE WATER PUMP ASSEMBLY
a. Remove the 17 bolts, water pump and gasket.
16. REMOVE TIMING CHAIN OR BELT COVER SUB-ASSEMBLY





a. Remove the 15 bolts and 2 nuts.





b. Remove the timing chain cover by prying 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.

c. Remove the O-ring from the LH cylinder head.
17. REMOVE TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL





a. Using a screwdriver, pry out the oil seal.

NOTICE: Be careful not to damage the oil pump assembly. Wrap the tip of the screwdriver with tape.





18. REMOVE CHAIN TENSIONER ASSEMBLY NO.1

NOTICE:
^ Never rotate the crankshaft with the chain tensioner removed.
^ When rotating the camshaft with the timing chain removed, rotate the crankshaft counterclockwise 40° from the TDC first.

a. While turning the stopper plate of the tensioner clockwise, push in the plunger of the chain tensioner as shown in the illustration.
b. While turning the stopper plate of the tensioner counterclockwise, insert a bar of [diameter]3.5 mm (0.138 inch) into the holes on the stopper plate and tensioner to fix the stopper plate.
c. Remove the 2 bolts and chain tensioner.
19. REMOVE CHAIN TENSIONER SLIPPER





20. REMOVE IDLE GEAR NO.1
a. Using a 10 mm hexagon wrench, remove the idle gear shaft No. 2, idle gear No. 1 and idle gear shaft No. 1.
21. REMOVE CHAIN VIBRATION DAMPER NO.2
a. Remove the 2 chain vibration damper No. 2.
22. REMOVE CHAIN SUB-ASSEMBLY
23. REMOVE CRANKSHAFT TIMING GEAR OR SPROCKET
24. REMOVE CHAIN VIBRATION DAMPER NO.1
a. Remove the 2 bolts and chain vibration damper No. 1.
25. REMOVE CAMSHAFT TIMING GEARS AND NO.2 CHAIN (RH BANK)





a. While raising the chain tensioner No. 2, insert a pin of [diameter]1.0 mm (0.039 inch) into the hole to fix it.





b. Hold the hexagonal portion of the camshaft with a wrench, and remove the 2 bolts, camshaft timing gear, camshaft timing gear assembly and timing chain No. 2.

NOTICE:
^ Be careful not to damage the cylinder head and valve lifter with the wrench.
^ Do not disassemble the camshaft timing gear assembly.