Disconnect the following engine wire harness connectors and wire harness clamps from the cylinder head:
•
•
•
•
•

Four injector connectors
ECT sensor 1 connector
CMP sensor connector
Secondary HO2S connector
Rocker arm oil control solenoid connector

10. Remove the harness holder and disconnect the breather hose.

Page 5 of 28

11. Remove the fuel pipe nut and the fuel pipe clamp. Hold a shop towel around the fuel pipe as fuel will leak out while
disconnecting.

FUEL PIPE CLAMP

j_
Replace.

~ FUEL PIPE NUT

10 N-m (7.2 lb-ft)

12. Remove the harness holder mounting bolts and the ground cable, then remove the harness holder.

13. Disconnect the upper radiator hose, the water bypass hose, and the heater hose from the cylinder head assembly.

UPPER RADIATOR

14. Remove the drive belt.
15. Remove the warm-up TWC.

Page 6 of 28

CAM CHAIN REMOVAL

1.

Turn the crankshaft so its white mark lines up with the pointer.

POINTER

2.

Remove the cylinder head cover.

3.

Check the No. 1 piston at top dead center. The "UP" mark on the camshaft sprocket should be at the top, and the
TDC grooves on the camshaft sprocket should line up with the top edge of the head.
TDC GROOVES

4.

Remove the right front wheel.

5.

Remove the splash shield.

6.

Remove the water pump pulley.

7.

Remove the crankshaft pulley.

8.

Support the engine with a jack and a wood block under the oil pan.

9.

Remove the ground cable, then remove the side engine mounUbracket assembly.

GROUND CABLE

SIDE ENGINE MOUNT/
BRACKET ASSEMBLY

Page 7 of 28

10. Remove the cam chain case.
CAM CHAIN CASE

11. Measure the cam chain separation. If the distance is less than the service limit, replace the cam chain and the cam
chain tensioner.

STANDARD DISTANCE: 19 mm (0.75 in)
SERVICE LIMIT: 15 mm (0.59 in)

12. Remove the cam chain tensioner and cam chain guides.

CAM CHAIN
TENSIONER SLIDER

~
CAM CHAIN
TENSIONER

~
13. Remove the cam chain.

r

'
CAM CHAIN GUIDE

Page 8 of 28

CYLINDER HEAD REMOVAL AND INSPECTION

1.

Remove the cylinder head bolts. To prevent warpage, loosen the bolts in sequence 1/3 turn at a time. Repeat this
sequence until all of the bolts are removed.

2.

Remove the cylinder head and visually inspect the head of the valves on the combustion side of the cylinder head
for damage.
NOTE: This is only a visual inspection looking for damage to the valves.
•
•

3.

Visually inspect each of the spark plugs for damaged or melted pieces of the center electrode or ground electrode.
•
•

4.

If any of the valves show any signs of damage, replace the cylinder head and go to CYLINDER BORE
INSPECTION.
If the valves are ok, go to step 3.

If any of the spark plug shows signs of damage, remove the valve closest to the damaged plug from the cylinder
head and go to step 4.
If the spark plugs are ok, go to CYLINDER BORE INSPECTION.

Visually inspect the cylinder head valve seat and the valve seat face for damage.
•
•

If there are any signs of damage (physical or local heat buildup) replace the cylinder head and go to CYLINDER
BORE INSPECTION.
If the valves and valves seats are ok, reassemble the cylinder head, and go to CYLINDER BORE
INSPECTION.

CYLINDER BORE INSPECTION

1.

Check the cylinder walls by rubbing your fingernail or a pencil with light pressure perpendicular to any vertical
scratches that are in the cylinder bore.
•

If your fingernail or a pencil does not catch on the scratches, the cylinder block is OK. Go to INSTALLATION OF
ENGINE SUPPORT.
•
If your finger nail or pencil catches on the scratches, replace the engine short block. Go to SHORT BLOCK
REPLACEMENT to replace the engine.
NOTE:
If the short block is replaced, it already has the counter-measured pistons and rings installed.
The oil pans that come with the short block aren't fully sealed. There is a gasket inside the oil pan that
needs to be installed before sealing the oil pan. For more information, refer to PIB 16-0001.

Normal honing marks shown .

Light scratches are not abnormal.
Ensure a fingernail or pencil "catches" on the
scratches before replacing the block.

Page 9 of 28

INSTALLATION OF ENGINE SUPPORT
1.

Use two support bars in a T-configuration to support the front end of the short block with a suitable strap through the
tensioner bracket.

OIL PAN REMOVAL
1.

Raise the vehicle.

2.

Drain the engine oil.

3.

Remove the driveshaft heat shield bolt from the engine oil pan.

4.

Remove the A/C compressor without disconnecting the A/C lines. Support the compressor with a strap to prevent it
from hanging on the A/C lines.

5.

Remove the dipstick, then remove the dipstick tube.

6.

Remove the CKP sensor cover, then disconnect and remove the CKP sensor connector.

BOLTS

10 N-m
(7.2 lb-ft)

CKPSENSOR
CONNECTOR

CKPSENSOR
COVER

Page 10 of 28

7.

Remove the transmission mounting bolts.
BOLTS

64 N-m (47 lb-ft)

8.

Remove the oil pan bolts.

Specified Torque

(D:

24 N-m (17 lb-ft)

®-@: 12 N-m (8.8 lb-ft)

9.

Using a flat-blade screwdriver, separate the oil pan from the engine block in the places shown.

10. Remove the oil pan.

I

NOTE: Lower the oil pan carefully to avoid damaging the IMA motor rotor position sensor.
11. Remove the oil screen.

Page 11 of 28

REMOVAL OF PISTONS AND RODS
NOTE: Before and during removal of pistons, rods, and caps, mark each piston top with the cylinder number and
direction mark towards the front of the engine.
1.

Prepare your work bench with a number location for each piston rod assembly to ensure the rods and caps are not
mixed as they are not interchangeable. The numbers stamped across the side of the rod and cap does not indicate
the cylinders they came from; they are a manufacturing number.

2.

Install the crank pulley and the key on the crank without the bolt.

3.

Beginning with cylinder No. 2 and 3 at Bottom Dead Center (BOC), rotate the crank slightly until the rod cap bolts
align with the holes on the main bearing cap bridge. Mark the caps to the rods with a grease pen as shown below.

Cylinder #2 and #3 rod cap bolts
shou ld be visible through these holes.

4.

Using a¼ inch drive 8 mm 12-point socket (Snap-On TMMD8 or equivalent), loosen and remove the rod caps for
cylinders No. 2 and 3, then set the caps on the bench next to the corresponding numbers.
Remove rod cap bolts.

Page 12 of 28

5.

Using a wooden or plastic handled hammer, gently push the pistons and rod assemblies No. 2 and 3 out of the
short block.

6.

Rotate the crankshaft 180 degrees, then repeat steps 3, 4, and 5 on cylinders No. 1 and 4.

7.

Visually inspect all connecting rod bearings for signs of damage.
NOTE: If your fingernail catches on a scratch or groove in the bearing, replace it. Pictured are normal, reusable rod
bearings after about 35,000 miles. Some discoloration is normal and does not require replacement.

8.

Reassemble the rod caps on the corresponding rods.

Reassemble.

Page 13 of 28

PISTON & PIN REPLACEMENT

sipecial Tools Required
Part Name

Tool Number

Quantity

Piston Base

07973-65700500 or
07973-65 7A500

1

Piston Base Head

07PAF-0010400 or
07PAF-001A400 or
07TGF-001 000A

1

Piston Base Head Insert

07PAF-0010500 or
07PAF-001A500 or
07TGF-001 000A

1

Insert Pin

07PAF-0010700 or
07PAF-001A700

1

Piston Base Spring

07973-6570600 or
07973-65 7A600

1

Pilot Collar OD 18 mm

070AF-PWC0130 or
070AF-PWCA 130

1

Insert Adjust

070AF-PWC0120 or
070AF-PWCA 120

1

Pilot Pin

070AF-PWC0110 or
070AF-PWCA 110

1

Disassembly
1.

Assemble the special tool as shown.

070AF-PWC0110

07973-6570600

Page 14 of 28

2.

Temporarily install the pilot collar over the pilot pin and adjust the piston base head insert as shown. Then tighten
the screws. Remove the pilot collar.
070AF-PWC0130
PILOT PIN

1mm

3.

1mm

.

Assemble and adjust the length of the insert pin and insert adjust to 44.5 mm.

...

44.5 mm (1.75 in) I

I

070AF-PWC0120

07PAF-0010700

4.

Starting with rod assembly No. 1, clearly mark the rod with the piston number. With the arrow on top of the piston
pointing up, place the piston assembly on the piston base head. Make sure you position the recessed flat area of
the piston against the piston base head insert as shown.

PIN
PISTON
ASSEMBLY

INSERT
PIN AND
INSERT
ADJUST

PILOT
COLLAR

Note the orientation of
the insert to the piston.

5.

Press the pin out with the insert pin, the insert adjust tool, the pilot collar, and a hydraulic press.

6.

Repeat steps 4 and 5 on pistons No. 2, 3, and 4. Do not reuse the old pistons and pins.

Page 15 of 28

7.

Starting with piston No. 1, assemble the piston and the connecting rod with the arrow and the embossed mark on
the same side.

EMBOSSED MARK

8.

Insert the pilot collar into the piston and the connecting rod.
INSERT PIN AND
INSERT ADJUST

'
7

44.5 mm

_l
PIN
PISTON
BASE HEAD

9.

With the arrow on top of the piston and the embossed mark on the connecting rod facing up, place the piston
assembly on the piston base head. Be sure you position the recessed flat area of the piston against the area of the
piston base head insert as shown.

10. Press the piston pin in using the insert pin, the insert adjust, and a hydraulic press.
11. Repeat steps 8 thru 10 with pistons No. 2, 3, and 4.

Page 16 of 28

Assemble New Rings on new pistons

1.

Install the rings as shown. The top ring has an "RC" mark, and the second ring has a "2R" mark. The manufacturing