ENGINE UNIT DISASSEMBLY

PROCEDURE

  1. REMOVE WATER BY-PASS PIPE

    A322753

    1. Remove the 3 bolts and water by-pass pipe.

    2. A324305

      Remove the 2 water by-pass pipe gaskets from the water by-pass pipe.

  2. REMOVE SPARK PLUG

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  3. REMOVE CAMSHAFT POSITION SENSOR

    Click here

  4. REMOVE ENGINE COOLANT TEMPERATURE SENSOR

    Click here

  5. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY

    Click here

  6. REMOVE CRANKSHAFT POSITION SENSOR

    Click here

  7. REMOVE KNOCK CONTROL SENSOR

    Click here

  8. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY

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  9. REMOVE OIL CONTROL VALVE FILTER

    A258551C01

    *a

    8 mm Hexagon Socket Wrench

    1. Using an 8 mm hexagon socket wrench, remove the head taper screw plug.

    2. A322749C01

      *1

      Oil Control Valve Filter

      *2

      Gasket

      *3

      Head Taper Screw Plug

      Remove the oil control valve filter and gasket.

  10. REMOVE OIL FILLER CAP SUB-ASSEMBLY

    A322750

    1. Remove the oil filler cap sub-assembly.

    2. A324292

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

  11. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY

    A322751

    1. Remove the 16 bolts and cylinder head cover sub-assembly.

  12. REMOVE CYLINDER HEAD COVER GASKET

    1. A323235

      Remove the cylinder head cover gasket from the cylinder head cover sub-assembly.

  13. REMOVE VENTILATION HOSE

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

    Click here

  15. REMOVE VENTILATION SYSTEM GROMMET

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  16. REMOVE GROMMET

    1. A324494

      Remove the 2 grommets from the cylinder head cover sub-assembly.

  17. REMOVE OIL PAN DRAIN PLUG

    A322752

    1. Remove the oil pan drain plug.

    2. Remove the oil pan drain plug gasket.

  18. REMOVE OIL PAN SUB-ASSEMBLY

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  19. REMOVE NO. 1 OIL PAN BAFFLE PLATE

    1. A324302

      Remove the 4 bolts and No. 1 oil pan baffle plate from the No. 2 oil pan sub-assembly.

  20. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY

    1. A324303

      Remove the 2 bolts and No. 2 oil pan sub-assembly from the oil pan sub-assembly.

  21. REMOVE RING PIN

    Tip:

    Perform this procedure only when replacement of the ring pin is necessary.

    1. A325956

      Remove the 2 ring pins.

  22. REMOVE OIL STRAINER SUB-ASSEMBLY

    1. A324300

      Remove the 3 bolts and oil strainer sub-assembly from the timing chain cover sub-assembly.

    2. A324301

      Remove the oil strainer gasket from the oil strainer sub-assembly.

  23. REMOVE WATER INLET

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  24. REMOVE THERMOSTAT

    Click here

  25. REMOVE ENGINE WATER PUMP ASSEMBLY

    Click here

  26. REMOVE OIL FILTER SUB-ASSEMBLY

    Click here

  27. REMOVE OIL FILTER BRACKET

    A322754

    1. Remove the 3 bolts and oil filter bracket.

    2. A322755

      Remove the oil filter bracket gasket from the timing chain cover sub-assembly.

  28. REMOVE TIMING GEAR COVER TIGHT PLUG

    Click here

  29. SET NO. 1 CYLINDER TO TDC/EXHAUST

    Click here

  30. REMOVE CRANKSHAFT PULLEY

    Click here

  31. REMOVE CYLINDER BLOCK DRAIN COCK PLUG

    1. A324313

      Remove the cylinder block drain cock plug and gasket.

  32. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY

    Click here

  33. REMOVE VENTILATION CASE SUB-ASSEMBLY

    1. A324476

      Remove the 2 bolts and ventilation case sub-assembly from the timing chain cover sub-assembly.

  34. REMOVE STUD BOLT

    Tip:

    Perform this procedure only when replacement of the stud bolt is necessary.

    1. A324478

      Remove the 2 stud bolts from the timing chain cover sub-assembly.

  35. REMOVE TIMING CHAIN COVER OIL SEAL

    1. A324479C02

      *a

      Protective Tape

      *b

      Wooden Block

      Using a wooden block and a screwdriver with its tip wrapped with protective tape, pry out the timing chain cover oil seal.

  36. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY

    1. A324314C02

      *a

      Stopper Plate

      Turn the stopper plate of the chain tensioner clockwise to release the lock and push in the plunger.

    2. A324315C02

      *a

      Hexagon Wrench

      *b

      Stopper Plate

      Turn the stopper plate counterclockwise to set the lock, and insert a hexagon wrench into the stopper plate hole.

    3. A324316

      Remove the 2 bolts and No. 1 chain tensioner assembly.

    4. A324625

      Remove the chain tensioner gasket from the No. 1 chain tensioner assembly.

  37. REMOVE TIMING CHAIN TENSION ARM

    1. A324317

      Remove the bolt and timing chain tensioner arm.

  38. REMOVE CHAIN SUB-ASSEMBLY

    1. Remove the chain sub-assembly.

  39. REMOVE TIMING CHAIN GUIDE

    1. A324318

      Remove the 2 bolts and timing chain guide.

  40. REMOVE CRANKSHAFT TIMING SPROCKET

    1. A324319

      Remove the crankshaft timing sprocket from the crankshaft.

  41. REMOVE CRANKSHAFT STRAIGHT PIN

    1. A324320

      Remove the crankshaft straight pin from the crankshaft.

  42. REMOVE CAMSHAFT TIMING SPROCKET ASSEMBLY

    1. A324321C01
      V100135

      Turn

      Rotate the crankshaft 90° clockwise.

      Note:

      Do not allow lifted valve and piston to come into contact with each other when removing the camshaft.

    2. A324322C01

      *a

      Turn

      *b

      Hold

      Using a wrench to hold the hexagonal portion of the camshaft, remove the bolt from the camshaft.

    3. Remove the camshaft timing sprocket assembly from the camshaft.

  43. REMOVE CAMSHAFT TIMING GEAR

    1. A324323C01

      *a

      Turn

      *b

      Hold

      Using a wrench to hold the hexagonal portion of the No. 2 camshaft, remove the bolt from the No. 2 camshaft.

    2. Remove the camshaft timing gear from the No. 2 camshaft.

  44. REMOVE CAMSHAFT BEARING CAP

    1. A324324C03

      *1

      No. 1 Camshaft Bearing Cap

      *2

      No. 2 Camshaft Bearing Cap

      Remove the 15 bolts in the order shown in the illustration.

    2. Remove the No. 1 camshaft bearing cap and No. 2 camshaft bearing caps.

  45. REMOVE NO. 2 CAMSHAFT

    1. A324325

      Remove the No. 2 camshaft from the cylinder head sub-assembly.

  46. REMOVE CAMSHAFT

    1. A324500

      Remove the camshaft from the cylinder head sub-assembly.

  47. REMOVE REAR ENGINE OIL SEAL RETAINER

    1. A324326

      Remove the 4 bolts and rear engine oil seal retainer from the cylinder block sub-assembly.

  48. REMOVE REAR ENGINE OIL SEAL

    A324328C02

    *a

    Protective Tape

    1. Using a screwdriver with its tip wrapped with protective tape, pry out the rear engine oil seal.

  49. REMOVE STUD BOLT

    Tip:

    Perform this procedure only when replacement of the stud bolt is necessary.

    1. A324327

      Using an E6 "TORX" socket wrench, remove the stud bolt from the rear engine oil seal retainer.

  50. REMOVE VALVE LIFTER

    1. A324329

      Remove the 12 valve lifters.

      Note:

      • Make a note of the inscribed mark on the valve lifters for each valve after removing them.

      • Arrange the valve lifters for each cylinder in the correct order.

  51. REMOVE CYLINDER HEAD SUB-ASSEMBLY

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  52. REMOVE CYLINDER HEAD GASKET

    Click here

  53. REMOVE CYLINDER BLOCK WATER JACKET SPACER

    1. A324424

      Remove the cylinder block water jacket spacer from the cylinder block sub-assembly.