Part One

Piston, Ring, Pin, and Connecting Rod Removal and Installation

Removal

1. Engine Wire Harness

1. Remove the engine wire harness.

2. Intermediate Shaft Assembly

1. Remove the intermediate shaft.

3. Clutch Cover

1. Remove the clutch case cover and the transmission mounting bolts.

4. Manual Transmission Assembly

1. Remove the transmission.

5. Pressure Plate

1. Install the ring gear holder.

2. Install the clutch alignment shaft and the remover handle.

3. To prevent warping, loosen the pressure plate mounting bolts (A) in a crisscross pattern in several steps.

4. Remove the pressure plate (B).

6. Clutch Disc

1. Remove the clutch disc (A), the clutch alignment shaft, and the remover handle.

7. Flywheel

1. Remove the flywheel (A).

NOTE: Loosen the flywheel mounting bolts (B) in a crisscross pattern in several steps.

2. Remove the ring gear holder.

8. Fuel Injector and Rail Assembly

1. Remove the rail with the fuel injector.

9. Intake Manifold and Throttle Body Assembly

1. Remove the intake manifold with the throttle body.

10. Injector Base Assembly

1. Remove the injector base (A).

11. A/F Sensor

1. Remove the A/F sensor.

12. WU-TWC

1. Remove the exhaust chamber cover.

2. Remove the WU-TWC.

13. Alternator

1. Remove the alternator.

14. Water Passage Assembly

1. Remove the water passage.

15. Starter

1. Remove the starter.

16. Ignition Coil Cover

1. Remove the ignition coil cover.

17. Ignition Coil

1. Remove the ignition coils.

18. Cylinder Head Cover

1. Remove the cylinder head cover.

19. Set The Crankshaft To Top Dead Center

1. Turn the crankshaft so its white mark (A) lines up with the pointer (B).

NOTE: The other pointer (C) is not used.

20. Set The No.1 Piston at Top Dead Center (With Cam Chain Case/Oil Pump)

1. Set the No. 1 piston at top dead center (TDC). The punch mark (A) on the VTC actuator and the punch mark (B) on the exhaust camshaft sprocket should be at the top. Align the TDC marks (C) on the VTC actuator and the exhaust camshaft sprocket.

21. Cam Chain Case Peripheral Assembly

1. Remove the harness clamp.

22. VTC Oil Control Solenoid Valve

1. Remove the ground cable (A).

2. Remove the VTC oil control solenoid valve (B).

23. Crankshaft Pulley

1. Hold the pulley with the holder handle (A) and the crankshaft pulley holder (B).

2. Remove the bolt with a socket, 19 mm (C) and a breaker bar, then remove the crankshaft pulley.

24. Side Engine Mount Bracket, Engine Side

1. Remove the side engine mount bracket.

25. Cam Chain Case

1. Remove the cam chain case (A) and the spacer (B).

26. Cam Chain Auto-Tensioner

1. Loosely install the crankshaft pulley.

2. Turn the crankshaft counterclockwise to compress the auto-tensioner.

3. Rotate the crankshaft counterclockwise to align the holes on the lock (A) and the auto-tensioner (B), then insert a 1.2 mm (3/64 in) diameter pin (C) into the holes. Turn the crankshaft clockwise to secure the pin.

NOTE: If the holes in the lock and the auto-tensioner do not align, continue to rotating the crankshaft counterclockwise until the holes align, then install the pin.

4. Remove the auto-tensioner.

27. Cam Chain Tensioner Arm and Cam Chain Guide

1. Remove cam chain guide B.

2. Remove cam chain guide A and the tensioner arm (B).

28. Cam Chain

1. Remove the cam chain.

29. Camshaft Holder

1. Loosen the rocker arm and the adjusting screws (A).

2. Remove the camshaft holder bolts. To prevent damaging the camshafts, loosen the bolts, in sequence, two turns at a time.

3. Remove cam chain guide B , the camshaft holders (A).

30. Camshaft

1. Remove the camshafts (A).

31. Rocker Arm Assembly

1. Insert the bolts (A) into the rocker shaft holder, then remove the rocker arm assembly (B).

32. Cylinder Head Assembly

1. Remove the cylinder head bolts. To prevent warpage, loosen the bolts in sequence 1/3 turn at a time; repeat the sequence until all bolts are loosened.

2. Remove the cylinder head.