ENGINE UNIT DISASSEMBLY

PROCEDURE


  1. REMOVE OIL FILLER CAP SUB-ASSEMBLY


    1. B008M6Q

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

  2. REMOVE OIL FILLER CAP GASKET


    1. B008L0O

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

  3. REMOVE ENGINE COVER JOINT


    1. B008MI5

      Remove the 2 engine cover joints.

  4. REMOVE SPARK PLUG

    Click here

  5. REMOVE CAMSHAFT POSITION SENSOR


  6. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY


  7. REMOVE CRANKSHAFT POSITION SENSOR

    Click here

  8. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY

    Click here

  9. REMOVE KNOCK SENSOR

    Click here

  10. REMOVE ENGINE COOLANT TEMPERATURE SENSOR

    Click here

  11. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY


    1. B008KM1

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

    2. B008KH2

      Remove the 3 gaskets from the camshaft bearing cap.

      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.

  12. REMOVE CYLINDER HEAD COVER GASKET


    1. B008KZX

      Remove the cylinder head cover gasket.

  13. REMOVE SPARK PLUG TUBE GASKET


    1. B008KNR

      Pry up the 4 claws of the ventilation baffle plate.

      Note

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

    2. Remove the 4 spark plug tube gaskets from the cylinder head cover sub-assembly.

      Note

      Be careful not to damage the cylinder head cover sub-assembly.

      Tech Tips

      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.

  14. REMOVE OIL FILTER

    Click here

  15. REMOVE OIL FILTER BRACKET CLIP (for Oil Filter Element Kit Type)


    1. B008M2W

      Remove the oil filter bracket clip from the oil filter bracket.

  16. REMOVE OIL FILTER UNION (for Oil Filter Sub-assembly Type)

    B008KSX

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

  17. SET NO. 1 CYLINDER TO TDC/COMPRESSION


    1. B008LZ8C04
      *a Timing Mark
      *b Timing Notch

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

    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.

      Tech Tips

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

  18. REMOVE CRANKSHAFT PULLEY

    Click here

  19. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY


    1. B008LYW

      Remove the 2 nuts, bracket, No. 1 chain tensioner assembly and gasket.

      Note

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

  20. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY

    Click here

  21. REMOVE TIMING CHAIN COVER OIL SEAL

    Click here

  22. REMOVE WATER INLET HOUSING


    1. B008MGT

      Remove the 3 bolts, water inlet housing and gasket.

  23. REMOVE NO. 1 GENERATOR BRACKET


    1. B008M99

      Remove the 4 bolts and No. 1 generator bracket.

  24. REMOVE CHAIN TENSIONER SLIPPER


    1. B008KOF

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

  25. REMOVE NO. 1 CHAIN VIBRATION DAMPER


    1. B008L1I

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

  26. REMOVE CHAIN SUB-ASSEMBLY


    1. B008L9F

      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.

    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.

      Tech Tips

      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.

  27. REMOVE CRANKSHAFT TIMING SPROCKET

    Click here

  28. REMOVE NO. 2 CHAIN SUB-ASSEMBLY

    Click here

  29. REMOVE NO. 1 CRANKSHAFT POSITION SENSOR PLATE


    1. B008MFR

      Remove the No. 1 crankshaft position sensor plate.

  30. REMOVE CRANKSHAFT TIMING GEAR KEY


    1. B008MEMC23
      *a Protective Tape

      Using a screwdriver, remove the 2 crankshaft timing gear keys.

      Tech Tips

      Tape the screwdriver tip before use.

  31. INSPECT CAMSHAFT TIMING GEAR ASSEMBLY

    Click here

  32. INSPECT CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY

    Click here

  33. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY

    Click here

  34. REMOVE CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY

    Click here

  35. REMOVE VALVE ROCKER ARM LOST MOTION DAMPER SUB-ASSEMBLY

    Click here

  36. INSTALL VALVE ROCKER ARM LOST MOTION DAMPER SUB-ASSEMBLY

    Click here

  37. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY

    Click here

  38. REMOVE CONTINUOUSLY VARIABLE VALVE LIFT CONTROLLER ASSEMBLY

    Click here

  39. REMOVE NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY


    1. B008K6Q

      Remove the 16 No. 1 valve rocker arm sub-assemblies.

      Tech Tips

      Arrange the removed parts in the correct order.

  40. REMOVE VALVE LASH ADJUSTER ASSEMBLY


    1. B008KZU

      Remove the 16 valve lash adjuster assemblies.

      Tech Tips

      Arrange the removed parts in the correct order.

  41. REMOVE VALVE STEM CAP


    1. B008KVJ

      Remove the 16 valve stem caps.

      Tech Tips

      Arrange the removed parts in the correct order.

  42. REMOVE CYLINDER HEAD SUB-ASSEMBLY

    Click here

  43. REMOVE CAMSHAFT HOUSING STRAIGHT PIN

    Note

    It is not necessary to remove a camshaft housing straight pin unless it is being replaced.

  44. REMOVE CYLINDER HEAD GASKET

    Click here

  45. REMOVE PCV VALVE (VENTILATION VALVE SUB-ASSEMBLY)

    Click here

  46. REMOVE OIL PAN DRAIN PLUG


    1. B008LUX

      Remove the oil pan drain plug and gasket.

  47. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY

    Click here

  48. REMOVE OIL PUMP ASSEMBLY

    Click here

  49. REMOVE REAR ENGINE OIL SEAL

    Click here

  50. REMOVE STIFFENING CRANKCASE ASSEMBLY


    1. B008KEH

      Uniformly loosen and remove the 11 bolts.

    2. B008KRNC10
      *a Protective Tape

      Using a screwdriver, remove the stiffening crankcase assembly by prying between the stiffening crankcase assembly and cylinder block sub-assembly.

      Note

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

      Tech Tips

      Tape the screwdriver tip before use.

  51. REMOVE NO. 1 TAPER SCREW PLUG


    1. B008KLC

      Remove the 2 No. 1 taper screw plugs.

  52. REMOVE STUD BOLT

    Note

    If a stud bolt is deformed or its threads are damaged, replace it.

  53. REMOVE STIFFENING CRANKCASE RING PIN

    Note

    It is not necessary to remove a stiffening crankcase ring pin unless it is being replaced.