Repair Procedures: Removal

Information 

Mark all wiring and hoses to avoid misconnection.

1. Shut off the high voltage circuit. (Refer to HIGH VOLTAGE SHUTOFF PROCEDURE ) .
2. Remove the engine cover.
3. Remove the air cleaner assembly. (Refer to ENGINE AND TRANSAXLE ASSEMBLY )
4. Remove the RH front wheel. (Refer to WHEEL )
5. Remove the under cover. (Refer to ENGINE AND TRANSAXLE ASSEMBLY )
6. Turn the crankshaft pulley and align its groove with the timing mark of the timing chain cover to set the piston of No. 1 cylinder to the top dead center on compression stroke.
   Fig 1: Timing Marks Aligned

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7. Disconnect the exhaust oil control valve (OCV) connector (A) and then remove the wiring from the cylinder head cover.
   Fig 2: Exhaust Oil Control Valve Connector

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8. Disconnect the positive crankcase ventilation (PCV) hose (A).
   Fig 3: Positive Crankcase Ventilation Hose

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9. Disconnect the ignition coil connectors (A) and then remove the wiring protector (B).
   Fig 4: Ignition Coil Connectors & Wiring Protector

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10. Remove the ignition coils (A).
    Fig 5: Ignition Coils

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11. Remove the cylinder head cover (A).
    Fig 6: Cylinder Head Cover

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12. Remove the water pump drive belt (A).
    Fig 7: Water Pump Drive Belt

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    1. Put the SST (09252-3D100) between the crankshaft pulley and the drive belt.
    2. Rotate the crankshaft pulley clockwise. Then the drive belt is removed.
    Fig 8: Removing Drive Belt

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13. Remove the drive belt.
    1. By rotating the #1 tensioner arm (A) counterclockwise, match the arm with the two tensioner stopper holes (B).
       Fig 9: Rotating #1 Tensioner Arm

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    2. Insert the stopper pin (A) into the stopper holes matched with the #1 tensioner (B).
    3. Remove the drive belt (C) after loosening the tension by rotating the #2 tensioner arm (D) clockwise.
    Fig 10: Rotating #2 Tensioner Arm

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14. Remove the A/C compressor bracket (A).
    Fig 11: A/C Compressor Bracket

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15. Drain the engine oil.
16. Remove the oil pan (A). Insert the blade of SST (09215-3C000) between the ladder frame and oil pan. Cut off applied sealer and remove the lower oil pan.
    Fig 12: Removing Oil Pan Using Blade Of SST (09215-3C000)

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    NOTE: Loosen one oil pan bolt near each corner of the oil pan leaving the bolts held in by about 2 threads. Then remove all other pan bolts.
    NOTE:

    • Insert the SST between the oil pan and the ladder frame by tapping it with a plastic hammer in the direction of arrow (1).
    • After tapping the SST with a plastic hammer along the direction of arrow (2) around more than 2/3 edge of the oil pan, remove it from the ladder frame.
    • Do not turn over the SST abruptly without tapping. It is result in damage of the SST.
    • Be careful not to damage the contact surfaces of ladder frame and lower oil pan.
17. Set the jack to the edge of ladder frame.
    NOTE:

    • Put the wooden block between ladder frame and jack.
    • Be careful not to damage the balance shaft & oil pump module.
18. Disconnect the ground line (A), and then remove the engine mounting support bracket (B).
    Fig 13: Ground Line & Engine Mounting Support Bracket

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19. Remove the crankshaft pulley (A) and the idler (B).
    Fig 14: Crankshaft Pulley & Idler

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20. Remove the water pump pulley (A) and the dust cover (B).
    Fig 15: Water Pump Pulley & Dust Cover

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21. Remove the engine support bracket (A).
    Fig 16: Engine Support Bracket

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22. Remove the timing chain cover (A) by gently prying the portions between the cylinder head and cylinder block.
    Fig 17: Timing Chain Cover

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    CAUTION: Be careful not to damage the contact surfaces of cylinder block, cylinder head and timing chain cover.
23. Make sure that the key of crankshaft is aligned with the mating surface of main bearing cap. As a result of this, the piston of No. 1 cylinder is placed at the top dead center on compression stroke.
24. Release the ratchet using a thin rod. Compress the piston and then insert a stopper pin (A) into the hole on the ratchet to hold the compressed piston. Remove the timing chain tensioner (B).
    Fig 18: Timing Chain Tensioner & Stopper Pin

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25. Remove the timing chain tensioner arm (A).
26. Remove the timing chain (B).
    Fig 19: Timing Chain Tensioner Arm & Timing Chain

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27. Remove the timing chain guide (A).
    Fig 20: Timing Chain Guide

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28. Remove the timing chain oil jet (A) and the crankshaft chain sprocket (B).
    Fig 21: Timing Chain Oil Jet & Crankshaft Chain Sprocket

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29. Remove the balance shaft chain.