Repair Procedures: Removal

Information 

Mark all wiring and hoses to avoid miss-connection.

1. Shut off the high voltage circuit. (Refer to High Voltage Shut-Off Procedures . )
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 Replacement . )
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: Aligning Groove With Timing Mark Of Timing Chain Cover

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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: Removing Exhaust Oil Control Valve Connector & Wiring From The Cylinder Head Cover

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

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

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

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

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12. Remove the water pump drive belt (A).
    Fig 7: Removing 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: Installing SST (09252-3D100) Between Crankshaft Pulley And 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: Removing Drive Belt By Rotating 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: Inserting Stopper Pin Into Stopper Holes

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14. Remove the A/C compressor bracket (A).
    Fig 11: Removing 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 By Inserting Blade Of SST (09215-3C000) Between Ladder Frame And Oil Pan

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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.
    • After tapping the SST with a plastic hammer along the direction of arrow 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: Removing Engine Mounting Support Bracket

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

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

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21. Remove the engine support bracket (A).
    Fig 16: Removing 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: Removing Timing Chain Cover

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    NOTE: 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: Inserting Stopper Pin Into Hole On Ratchet

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

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

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

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29. Remove the balance shaft chain.