ENGINE UNIT DISASSEMBLY

PROCEDURE

  1. REMOVE OIL FILLER CAP SUB-ASSEMBLY

    1. A150846

      Remove the oil filler cap sub-assembly.

  2. REMOVE OIL FILLER CAP GASKET

    1. A128159

      Remove the oil filler cap gasket.

  3. REMOVE ENGINE COVER JOINT

    1. A150847

      Remove the 2 engine cover joints.

  4. REMOVE SPARK PLUG

    Click here

  5. REMOVE CAMSHAFT POSITION SENSOR (for Intake Side)

    Click here

  6. REMOVE CAMSHAFT POSITION SENSOR (for Exhaust Side)

    Click here

  7. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Intake Side)

    Click here

  8. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Exhaust Side)

    Click here

  9. REMOVE CRANKSHAFT POSITION SENSOR

    Click here

  10. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY

    Click here

  11. REMOVE KNOCK SENSOR

    Click here

  12. REMOVE ENGINE COOLANT TEMPERATURE SENSOR

    Click here

  13. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY

    1. A150850

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

    2. A150852

      Remove the 3 gaskets from the camshaft bearing cap.

      Note:

      As gaskets may stick to the cylinder head cover, be careful not to drop any of the gaskets into the engine when removing the cylinder head cover.

  14. REMOVE CYLINDER HEAD COVER GASKET

    1. A150851

      Remove the cylinder head cover gasket.

  15. REMOVE SPARK PLUG TUBE GASKET

    1. A152586

      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. A337770

      Using a screwdriver as shown in the illustration, deform each spark plug tube gasket inwards and remove the 4 spark plug tube gaskets from cylinder head cover sub-assembly.

      Note:

      • As much as possible prevent the spark plug tube gaskets from being deformed.

      • Do not damage the spark plug tube gasket and cylinder head cover sub-assembly.

      • Make sure not to damage the spark plug tube gasket and cylinder head cover sub-assembly when inserting the screwdriver in the joint area.

      Tip:

      If the cylinder head cover sub-assembly is damaged, smooth the surface with 400-grid sandpaper.

  16. REMOVE OIL FILTER CAP ASSEMBLY

    Click here

  17. SET NO. 1 CYLINDER TO TDC/COMPRESSION

    1. A404240C01

      *a

      Timing Mark

      *b

      Timing Notch

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

    2. Check that the timing marks on both the camshaft timing exhaust gear and camshaft timing gear are facing upward as shown in the illustration.

      Tip:

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

  18. REMOVE CRANKSHAFT PULLEY

    Click hereClick here

  19. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY

    1. A250765

      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 ENGINE MOUNTING BRACKET STUD BOLT

    1. A211980

      Remove the engine mounting bracket stud bolt.

  21. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY

    Click here

  22. REMOVE TIMING CHAIN COVER OIL SEAL

    Click here

  23. REMOVE WATER INLET HOUSING

    1. A150906

      Remove the 3 bolts, water inlet housing and gasket.

  24. REMOVE NO. 1 GENERATOR BRACKET

    1. A150905

      Remove the 4 bolts and No. 1 generator bracket.

  25. REMOVE CHAIN TENSIONER SLIPPER

    A150870

  26. REMOVE NO. 1 CHAIN VIBRATION DAMPER

    1. A165280

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

  27. REMOVE NO. 2 CHAIN VIBRATION DAMPER

    Click here

  28. REMOVE CHAIN SUB-ASSEMBLY

    1. A251821C01

      *a

      Turn

      *b

      Place the Chain on the Gear

      *c

      Loosen the Chain

      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 gears.

    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.

      Tip:

      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.

  29. REMOVE CRANKSHAFT TIMING SPROCKET

    Click here

  30. REMOVE NO. 2 CHAIN SUB-ASSEMBLY

    Click here

  31. REMOVE NO. 1 CRANKSHAFT POSITION SENSOR PLATE

  32. REMOVE CRANKSHAFT TIMING GEAR KEY

    1. A150909C07

      *1

      Protective Tape

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

      Tip:

      Tape the screwdriver tip before use.

  33. INSPECT CAMSHAFT TIMING GEAR ASSEMBLY

    Click here

  34. INSPECT CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY

    Click here

  35. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY

    Click here

  36. REMOVE CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY

    Click here

  37. REMOVE CAMSHAFT BEARING CAP

    Click here

  38. REMOVE CAMSHAFT

    Click here

  39. REMOVE NO. 2 CAMSHAFT

    Click here

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

    1. A332534

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

      Tip:

      Arrange the removed parts in the correct order.

  41. REMOVE VALVE LASH ADJUSTER ASSEMBLY

    1. A297858

      Remove the 16 valve lash adjuster assemblies from the cylinder head.

      Tip:

      Arrange the removed parts in the correct order.

  42. REMOVE OIL CONTROL VALVE FILTER

    1. A150883

      Remove the oil control valve filter from the No. 1 camshaft bearing cap.

  43. REMOVE NO. 1 CAMSHAFT BEARING

    Click here

  44. REMOVE NO. 2 CAMSHAFT BEARING

    Click here

  45. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY

    Click here

  46. REMOVE VALVE STEM CAP

    1. A150945

      Remove the 16 valve stem caps.

      Tip:

      Arrange the removed parts in the correct order.

  47. REMOVE CAMSHAFT HOUSING STRAIGHT PIN

    Note:

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

  48. REMOVE CYLINDER HEAD SUB-ASSEMBLY

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  49. REMOVE CYLINDER HEAD GASKET

    Click here

  50. REMOVE PCV VALVE SUB-ASSEMBLY

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  51. REMOVE OIL PAN DRAIN PLUG

    1. A150893

      Remove the oil pan drain plug and gasket.

  52. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY

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  53. REMOVE OIL PUMP ASSEMBLY

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  54. REMOVE ENGINE REAR OIL SEAL

    Click hereClick here

  55. REMOVE STIFFENING CRANKCASE ASSEMBLY

    1. A150897

      Uniformly loosen and remove the 11 bolts.

    2. A150898C09

      *1

      Protective Tape

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

      Note:

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

      Tip:

      Tape the screwdriver tip before use.

  56. REMOVE NO. 1 TAPER SCREW PLUG

    1. A300838

      Remove the No. 1 taper screw plug.

  57. REMOVE STUD BOLT

    Note:

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

  58. REMOVE STIFFENING CRANKCASE RING PIN

    Note:

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