Remove the oil filler cap sub-assembly from the cylinder head cover sub-assembly.

Remove the oil filler cap gasket from the oil filler cap sub-assembly.

Remove the 2 engine cover joints from the cylinder head cover sub-assembly.

1.333,0.885 1.656,0.615 1.656,0.615 1.802,0.615 false 1.865,0.521 2.177,0.719 0.313,0.198 10 false *1

*1	Seal Washer

Remove the 13 bolts, seal washer and cylinder head cover sub-assembly from the camshaft housing sub-assembly.

Remove the 3 gaskets from the camshaft bearing cap.

NOTICE:

As gaskets may stick to the cylinder head cover sub-assembly, be careful not to drop any of the gaskets into the engine when removing the cylinder head cover sub-assembly.

Remove the cylinder head cover gasket from the cylinder head cover sub-assembly.

1.708,1.302 2.26,0.365 2.26,0.365 2.51,0.365 false 2.563,0.292 2.875,0.448 0.313,0.156 10 false *a 2.031,2.656 2.229,2.844 0.198,0.188 10 true *b

*a	Ventilation Baffle Plate
*b	Pry up

Pry up the 4 claws of the ventilation baffle plate.

NOTICE:

Do not deform the claws of the ventilation baffle plate more than necessary.

Using a screwdriver as shown in the illustration, deform each spark plug tube gasket inwards and remove the 4 spark plug tube gaskets from the cylinder head cover sub-assembly.

NOTICE:

·

As much as possible prevent the spark plug tube gaskets from being deformed.

The removed spark plug tube gaskets will be used when reinstalling the new spark plug tube gaskets.

·

Do not damage the cylinder head cover sub-assembly.

·

Make sure not to damage the spark plug tube gasket and cylinder head cover sub-assembly when inserting the screwdriver in the joint area.

HINT:

If the cylinder head cover sub-assembly is damaged, smooth the surface with 400-grit sandpaper.

i.

0.719,0.344 1.031,0.542 0.313,0.198 10 *a 2.573,0.354 2.885,0.552 0.313,0.198 10 *b

*a	Before cutting off
*b	After cutting off
	Area to be cut off

Using a cutter, cut off the sealing part of the removed spark plug tube gasket.

Remove the 2 nuts, bracket, No. 1 chain tensioner assembly and gasket.

NOTICE:

Do not turn the crankshaft without the No. 1 chain tensioner assembly installed.

Remove the stud bolt from the engine mounting bracket RH.

NOTICE:

If a stud bolt is deformed or its threads are damaged, replace it.

Remove the 3 bolts and engine mounting bracket RH from the timing chain cover sub-assembly.

Remove the 4 bolts and oil filter bracket from the timing chain cover sub-assembly.

Remove the 2 O-rings from the timing chain cover sub-assembly.

1.729,1.656 2.146,0.198 2.146,0.198 2.333,0.198 true 2.375,0.115 2.688,0.313 0.313,0.198 10 false *1

*1	Seal Washer

Remove the 19 bolts and seal washer.

0.74,0.458 1.25,0.25 1.25,0.25 1.417,0.25 true 2.5,0.5 2.667,0.5 2.667,0.5 2.958,1.156 true 2,4.417 2.167,4.417 2.167,4.417 2.969,3.906 true 0.604,4.26 1.25,4.167 1.25,4.167 1.417,4.167 true 1.448,0.177 1.76,0.333 0.313,0.156 10 false *a 2.333,0.427 2.646,0.583 0.313,0.156 10 false *a 1.823,4.344 2.135,4.5 0.313,0.156 10 false *a 1.458,4.094 1.771,4.25 0.313,0.156 10 false *a

*a	Protective Tape

Remove the timing chain cover sub-assembly by prying between the timing chain cover sub-assembly and cylinder head sub-assembly or cylinder block sub-assembly with a screwdriver as shown in the illustration.

NOTICE:

Be careful not to damage the contact surfaces of the cylinder head sub-assembly, camshaft housing sub-assembly, cylinder block sub-assembly, stiffening crankcase assembly and timing chain cover sub-assembly.

HINT:

Tape the screwdriver tip before use.

Remove the O-ring from the cylinder block sub-assembly.

Remove the 3 bolts and engine water pump assembly from the timing chain cover sub-assembly.

Remove the water pump gasket from the timing chain cover sub-assembly.

2.188,1.896 2.448,1.792 2.448,1.792 2.521,1.573 false 0.573,1.844 0.708,1.844 0.708,1.844 1.563,1.24 true 2.49,1.781 2.802,1.979 0.313,0.198 10 false *a 0.396,1.771 0.708,1.969 0.313,0.198 10 false *b

*a	Wooden Block
*b	Protective Tape

Place the timing chain cover sub-assembly on wooden blocks.

Using an E5 "TORX" socket wrench, remove the 2 water inlet housing stud bolts.

Remove the 3 bolts, gasket and water inlet housing from the timing chain cover sub-assembly.

Remove the 4 bolts and No. 1 generator bracket from the cylinder block sub-assembly.

Remove the 2 bolts and No. 2 chain vibration damper from the camshaft bearing cap.

Remove the chain tensioner slipper from the cylinder block sub-assembly.

Remove the 2 bolts and No. 1 chain vibration damper.

Remove the crankshaft timing sprocket from the crankshaft.

1.125,0.635 0.656,0.229 false 1.406,0.542 0.656,0.229 false 0.333,0.146 0.656,0.323 0.323,0.177 10 false SST

Using SST, hold the crankshaft pulley. Then remove the oil pump drive shaft gear nut.

SST

09213-54015  09330-00021  

HINT:

Part number of installation bolt for SST (crankshaft pulley holding tool): 91551-00850 (quantity: 2)

0.979,1.333 1.271,1.333 false 0.771,0.906 1.01,0.906 1.01,0.906 1.635,1.135 true 0.375,1.781 0.531,1.781 false 0.792,1.25 1.104,1.448 0.313,0.198 10 false *1 0.604,0.833 0.917,1.031 0.313,0.198 10 false *2 0.219,1.698 0.531,1.896 0.313,0.198 10 false *a

*1	Chain Tensioner Plate
*2	Chain Damper Spring
*a	Bolt

Remove the bolt, chain tensioner plate and chain damper spring.

0.979,1.219 1.104,1.219 1.104,1.219 1.302,1.833 false 1.292,0.542 1.417,0.542 1.417,0.542 1.813,1.49 false 1.417,2.521 1.552,2.521 1.552,2.521 1.708,2.74 false 1.146,0.458 1.458,0.615 0.313,0.156 10 *1 0.802,1.135 1.115,1.292 0.313,0.156 10 *2 1.229,2.458 1.542,2.615 0.313,0.156 10 *3

*1	No. 2 Chain Sub-assembly
*2	Oil Pump Drive Gear
*3	Oil Pump Drive Shaft Gear

Remove the oil pump drive gear, oil pump drive shaft gear and No. 2 chain sub-assembly.

Remove the No. 1 crankshaft position sensor plate.

0.854,0.719 0.969,0.719 0.969,0.719 1.177,1.292 false 0.698,0.635 0.875,0.813 0.177,0.177 10 *a

*a	Protective Tape

Using a screwdriver, remove the 2 crankshaft timing gear keys.

HINT:

Tape the screwdriver tip before use.

Release the lock pin.

NOTICE:

Before removing the camshaft timing gear assembly, make sure that the lock pin has been released.

i.

2.792,0.885 2.635,0.281 2.635,0.281 2.438,0.281 false 1.49,1.635 0.854,2.927 true 1.656,1.646 2.656,2.865 2.656,2.865 2.844,1.25 true 2.25,0.188 2.448,0.385 0.198,0.198 10 *a 2.604,2.896 2.802,3.083 0.198,0.188 10 *b 0.771,2.979 0.969,3.177 0.198,0.198 10 *c

*a	Adhesive Tape Sealing Area
*b	Make a Hole
*c	Adhesive Tape

After cleaning the intake side VVT oil hole in the camshaft bearing cap, completely seal the oil hole with adhesive tape or equivalent as shown in the illustration to prevent air from leaking.

NOTICE:

Be sure to cover the oil hole completely because air leaks due to insufficient sealing will prevent the lock pin from being released.

iii.

Apply approximately 150 kPa (1.5 kgf/cm², 22 psi) of air pressure to the hole pricked in procedure (A) to release the lock pin.

NOTICE:

·

If air leaks out, reattach the adhesive tape.

·

Cover the oil hole with a piece of cloth when applying air pressure to prevent oil from spraying.

·

Do not lock the camshaft timing gear assembly. If it is locked, release the lock pin again.

HINT:

·

Depending on the air pressure applied, the camshaft timing gear assembly may turn in the advance direction without assistance by hand.

·

If enough air pressure cannot be applied because of air leakage from the port, releasing the lock pin may be difficult.

1.177,1.583 1.708,1.781 1.708,1.781 1.313,1.396 false 0.479,1.438 0.479,1.75 false 0.938,1.229 1.708,1.781 1.708,1.781 1.115,0.99 false 1.75,1.76 1.927,1.927 0.177,0.167 10 false *b 0.396,1.771 0.583,1.917 0.188,0.146 10 false *a

*a	Bolt
*b	Do not remove

Remove the bolt while holding the hexagonal portion of the camshaft, and then remove the camshaft timing gear assembly.

NOTICE:

·

Do not remove the other 4 bolts.

·

Keep the camshaft timing gear assembly horizontal while removing it from the camshaft.

0.958,0.906 0.771,0.167 0.771,0.167 1.188,1.083 false 0.969,1.438 1.5,1.875 1.5,1.875 1.208,1.563 false 0.563,1.833 0.479,1.833 0.479,1.833 0.313,1.563 false 1.531,1.781 1.708,1.948 0.177,0.167 10 false *b 0.552,0.042 0.74,0.198 0.188,0.156 10 false *b 0.573,1.729 0.74,1.906 0.167,0.177 10 false *a

*a	Bolt
*b	Do not remove

Remove the bolt while holding the hexagonal portion of the No. 2 camshaft, then remove the camshaft timing exhaust gear assembly.

NOTICE:

·

Do not remove the other 4 bolts.

·

Keep the camshaft timing exhaust gear assembly horizontal while removing it from the No. 2 camshaft.

0.729,0.458 0.938,0.74 0.208,0.281 10 1 0.771,1.542 0.979,1.823 0.208,0.281 10 2 1.365,0.427 1.573,0.708 0.208,0.281 10 5 1.917,0.427 2.125,0.708 0.208,0.281 10 9 2.438,0.417 2.625,0.708 0.188,0.292 10 7 2.948,0.427 3.135,0.719 0.188,0.292 10 3 1.406,1.552 1.615,1.833 0.208,0.281 10 6 1.948,1.563 2.156,1.844 0.208,0.281 10 10 2.438,1.563 2.646,1.844 0.208,0.281 10 8 2.958,1.563 3.167,1.844 0.208,0.281 10 4

Uniformly loosen and remove the 10 bolts in the order shown in the illustration.

0.781,1.875 0.948,2.042 0.167,0.167 10 1 0.781,0.073 1.021,0.271 0.24,0.198 10 2 0.229,1.281 0.396,1.448 0.167,0.167 10 3 2.917,1.833 3.083,2 0.167,0.167 10 4 2.958,0.219 3.177,0.51 0.219,0.292 10 5 2.375,1.344 2.521,1.49 0.146,0.146 10 6 1.396,1.833 1.542,1.979 0.146,0.146 10 7 1.365,0.156 1.583,0.427 0.219,0.271 10 8 0.823,1.344 1,1.521 0.177,0.177 10 9 2.385,1.823 2.563,2 0.177,0.177 10 10 1.802,1.344 1.979,1.521 0.177,0.177 10 12 2.313,0.156 2.573,0.438 0.26,0.281 10 11 1.875,1.823 2.052,2 0.177,0.177 10 13 1.885,0.177 2.125,0.448 0.24,0.271 10 14 1.292,1.344 1.5,1.531 0.208,0.188 10 15

Uniformly loosen and remove the 15 bolts in the order shown in the illustration.

NOTICE:

Uniformly loosen the bolts while keeping the camshaft and No. 2 camshaft level.

Remove the camshaft from the camshaft housing sub-assembly.

Remove the No. 2 camshaft from the camshaft housing sub-assembly.

Remove the 16 No. 1 valve rocker arm sub-assemblies.

HINT:

Arrange the removed parts in the correct order.

Remove the 16 valve lash adjuster assemblies from the cylinder head sub-assembly.

HINT:

Arrange the removed parts in the correct order.

Remove the oil control valve filter from the camshaft bearing cap.

Remove the 2 No. 2 camshaft bearings from the camshaft housing sub-assembly.

NOTICE:

Arrange the removed parts in the correct order.

Remove the 2 bolts.

0.698,2.583 1.646,4.135 1.646,4.135 1.875,3.188 true 1.594,4.167 1.771,4.323 0.177,0.156 10 *a

*a	Protective Tape

Remove the camshaft housing sub-assembly by prying between the cylinder head sub-assembly and camshaft housing sub-assembly with a screwdriver.

NOTICE:

Be careful not to damage the contact surfaces of the cylinder head sub-assembly and camshaft housing sub-assembly.

HINT:

Tape the screwdriver tip before use.

Remove the oil pan drain plug and gasket.

0.229,1.875 0.542,2.073 0.313,0.198 10 false *a 2.948,1.74 3.135,1.906 0.188,0.167 10 true *a

*a

Nut

Remove the 10 bolts and 2 nuts.

Insert the blade of an oil pan seal cutter between the stiffening crankcase assembly and No. 2 oil pan sub-assembly. Cut through the applied sealer and remove the No. 2 oil pan sub-assembly.

NOTICE:

Be careful not to damage the contact surfaces of the stiffening crankcase assembly and No. 2 oil pan sub-assembly.

Uniformly loosen and remove the 11 bolts.

0.406,3.094 0.406,4.115 true 0.417,4.031 3.125,4.031 3.125,4.031 3.125,2.688 true 2.427,3.354 2.427,4.031 true 1.271,3.521 1.271,4.031 true 0.333,4.135 0.5,4.323 0.167,0.188 10 *a

*a	Protective Tape

Using a screwdriver, remove the stiffening crankcase assembly by prying between the stiffening crankcase assembly and cylinder block sub-assembly.

NOTICE:

Be careful not to damage the contact surfaces of the stiffening crankcase assembly and cylinder block sub-assembly.

HINT:

Tape the screwdriver tip before use.

Remove the No. 1 taper screw plug.

Remove the 2 stiffening crankcase ring pins from the stiffening crankcase assembly.

Using an E6 "TORX" socket wrench, remove the 2 stiffening crankcase stud bolts from the stiffening crankcase assembly.

Remove the rear engine oil seal from the cylinder block sub-assembly.