Disassembly [01/2019 - 03/2019]: Procedure

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

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

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Refer to PROCEDURE - Step 2

Refer to PROCEDURE - Step 1

Refer to PROCEDURE - Step 1

• for Intake Side:

  Refer to PROCEDURE - Step 1

• for Exhaust Side:

  Refer to PROCEDURE - Step 2

Refer to PROCEDURE - Step 1

Refer to PROCEDURE - Step 1

Refer to PROCEDURE - Step 2

Refer to PROCEDURE - Step 3

1. Remove the 13 bolts, seal washer and cylinder head cover sub-assembly.

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2. Remove the 3 gaskets from the camshaft bearing cap.

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   NOTE:

   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.

1. Remove the cylinder head cover gasket.

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1. Pry up the 4 claws of the ventilation baffle plate.

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   NOTE:

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

2. 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.

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   NOTE:

   • 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.
   • Prevent the spark plug tube gaskets from being deformed as much as possible. The removed spark plug tube gaskets will be used when installing new spark plug tube gaskets.
   1. Using a cutter, cut off the sealing part of the removed plug tube gasket.

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

Refer to PROCEDURE - Step 3

1. Using a 12 mm hexagon socket wrench, remove the oil filter union from the oil filter bracket.

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1. Turn the crankshaft pulley until its timing notch and timing mark "0" of the timing chain cover sub-assembly are aligned.

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   *a	Timing Mark
   *b	Timing Notch

2. Check that timing marks on both the camshaft timing exhaust gear assembly and camshaft timing gear assembly are facing upward as shown in the illustration.

   HINT: 

   If not, turn the crankshaft 1 complete revolution (360°) and align the marks as above.

Refer to PROCEDURE - Step 6

1. Remove the 2 nuts, bracket, No. 1 chain tensioner assembly and gasket from the timing chain cover sub-assembly.

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   NOTE:

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

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

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

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

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4. Remove the 19 bolts and seal washer.

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   *1	Seal Washer

5. Remove the timing chain cover sub-assembly by prying between the timing chain cover sub-assembly and cylinder head sub-assembly, camshaft housing sub-assembly, cylinder block sub-assembly and stiffening crankcase assembly with a screwdriver as shown in the illustration.

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   *a	Protective Tape

   NOTE:

   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.

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

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7. Remove the 2 O-rings from the cylinder head sub-assembly.
8. Remove the 3 bolts and engine water pump assembly from the timing chain cover sub-assembly.

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9. Remove the gasket from the timing chain cover sub-assembly.

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1. Using a screwdriver and hammer, remove the timing chain cover oil seal.

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   *a	Protective Tape
   *b	Wooden Block

   NOTE:

   Be careful not to damage the timing chain cover sub-assembly.

   HINT: 

   Tape the screwdriver tip before use.

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

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

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

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

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

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1. Hold the hexagonal portion of the camshaft with a wrench and turn the camshaft timing gear assembly counterclockwise to loosen the chain sub-assembly between the camshaft timing exhaust gear assembly and camshaft timing gear assembly.

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2. With the chain sub-assembly loosened, release the chain sub-assembly from the camshaft timing gear assembly and place it on the camshaft timing gear assembly.

   HINT: 

   Be sure to release the chain sub-assembly from the sprocket completely.

3. Turn the camshaft clockwise to return it to the original position and remove the chain sub-assembly.

1. Remove the crankshaft timing sprocket from the crankshaft.

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1. Temporarily install the crankshaft pulley with the crankshaft pulley bolt.

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2. Using SST, hold the crankshaft pulley. Then remove the oil pump drive shaft gear nut.
   • SST: 09213-54015 
     1. 91551-00850
   • SST: 09330-00021 
3. Remove SST, the crankshaft pulley bolt and crankshaft pulley.
4. Remove the bolt, chain tensioner plate and chain damper spring.

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   *1	Chain Damper Spring
   *2	Chain Tensioner Plate

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

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

1. Remove the No. 1 crankshaft position sensor plate.

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1. Using a screwdriver with its tip wrapped with protective tape, remove the 2 crankshaft timing gear keys from the crankshaft.

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   *a	Protective Tape

1. Inspect the lock of the camshaft timing gear assembly.
2. After cleaning the VVT oil hole in the intake side of the No. 1 camshaft bearing cap, completely seal the oil hole with adhesive tape or equivalent as shown in the illustration to prevent air from leaking.

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

   NOTE:

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

3. Prick a hole in the tape covering the oil hole as shown in the illustration. (Procedure A)
4. 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.

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   NOTE:

   • 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.
5. Forcibly turn the camshaft timing gear assembly in the advance direction (counterclockwise).

   HINT: 

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

6. Turn the camshaft timing gear assembly within its movable range (26.5 to 28.5°) 2 or 3 times without turning it to the most retarded position. Make sure that the camshaft timing gear assembly turns smoothly.

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7. Remove the adhesive tape from the No. 1 camshaft bearing cap.

1. Check the lock of the camshaft timing exhaust gear assembly.
2. After cleaning the VVT oil hole in the exhaust side of the No. 1 camshaft bearing cap, completely seal the oil hole with adhesive tape or equivalent as shown in the illustration to prevent air from leaking.

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

   NOTE:

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

3. Prick a hole in the tape covering the oil hole as shown in the illustration. (Procedure A)
4. Apply approximately 200 kPa (2.0 kgf/cm² , 29 psi) of air pressure to the hole pricked in procedure A to release the lock pin.

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   NOTE:

   • 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.
5. Using a screwdriver with its tip wrapped with protective tape, forcibly turn the camshaft timing exhaust gear assembly in the retard direction (clockwise).
   NOTE:

   • Be sure to keep the camshaft timing exhaust gear assembly in the retard direction using a screwdriver. If the gear is released, it will return to the most advanced position automatically due to the force from the spring.
   • Do not damage the camshaft timing exhaust gear assembly.
6. Using a screwdriver with its tip wrapped with protective tape, turn the camshaft timing exhaust gear assembly within its movable range (19 to 21°) 2 or 3 times without turning it to the most advanced position. Make sure that the camshaft timing exhaust gear assembly turns smoothly.

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7. Remove the adhesive tape from the No. 1 camshaft bearing cap.

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

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   *a	Do not remove

   NOTE:

   • Before removing the camshaft timing gear assembly, make sure that the lock pin has been released.
   • Be sure not to remove the other 4 bolts.
   • Keep the camshaft timing gear assembly horizontal while removing it from the camshaft.

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

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   *a	Do not remove

   NOTE:

   • Be sure not to remove the other 4 bolts.
   • Keep the camshaft timing exhaust gear assembly horizontal while removing it from the No. 2 camshaft.

Refer to PROCEDURE - Step 6

Refer to PROCEDURE - Step 7

Refer to PROCEDURE - Step 8

Refer to PROCEDURE - Step 8

1. Remove the 16 No. 1 valve rocker arm sub-assemblies from the cylinder head sub-assembly.

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   HINT: 

   Arrange the removed parts in such a way that they can be reinstalled to their original locations.

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

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   HINT: 

   Arrange the removed parts in such a way that they can be reinstalled to their original locations.

1. Remove the 16 valve stem caps.

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   HINT: 

   Arrange the removed parts in the correct order.

Refer to PROCEDURE - Step 3

Refer to PROCEDURE - Step 4

Refer to PROCEDURE - Step 3

1. Remove the oil pan drain plug and gasket from the No. 2 oil pan sub-assembly.

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1. Remove the 10 bolts and 2 nuts from the No. 2 oil pan sub-assembly.

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2. 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.

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   NOTE:

   • Be careful not to damage the surface of the No. 2 oil pan sub-assembly which contacts the stiffening crankcase assembly.
   • Be careful not to damage the stiffening crankcase assembly flange.

Refer to PROCEDURE - Step 38

1. Uniformly loosen and remove the 11 bolts from the stiffening crankcase assembly.

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2. Remove the stiffening crankcase assembly by prying between the stiffening crankcase assembly and cylinder block sub-assembly with a screwdriver with its tip wrapped with protective tape.

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   *a	Protective Tape

   NOTE:

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

1. Remove the No. 1 taper screw plug.

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Refer to PROCEDURE - Step 5