ENGINE UNIT DISASSEMBLY

PROCEDURE


  1. REMOVE VACUUM PUMP ASSEMBLY

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  2. REMOVE KNOCK CONTROL SENSOR

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  3. REMOVE OIL PRESSURE SENDER GAUGE ASSEMBLY

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  4. REMOVE ENGINE COOLANT TEMPERATURE SENSOR

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  5. REMOVE ENGINE COVER JOINT


    1. A01W1BD

      Remove the 2 engine cover joints.

  6. REMOVE SPARK PLUG

    Click here

  7. REMOVE OIL FILLER CAP SUB-ASSEMBLY


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

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

  8. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY

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  9. REMOVE CAMSHAFT POSITION SENSOR (for Intake Side)

    Click here

  10. REMOVE CAMSHAFT POSITION SENSOR (for Exhaust Side)

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

    Click here

  12. REMOVE NO. 1 VENTILATION CASE


    1. A01W59T

      Remove the 8 bolts and 2 nuts.

      Text in Illustration
      B001O8N Bolt
      B001OAO Nut
    2. A01W599

      Remove the No. 1 ventilation case by prying between the No. 1 ventilation case and cylinder block sub-assembly with a screwdriver.

      Note

      Be careful not to damage the contact surfaces of the cylinder block sub-assembly and No. 1 ventilation case.

      Tech Tips

      Tape the screwdriver tip before use.

  13. REMOVE CRANKSHAFT POSITION SENSOR

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  14. REMOVE CRANKSHAFT PULLEY


    1. A01W509E01
      Text in Illustration
      *a Hold
      *b Turn

      Using SST, hold the crankshaft pulley and loosen the crankshaft pulley set bolt. Further loosen the crankshaft pulley set bolt until 2 or 3 threads are screwed into the crankshaft.

      SST
      09213-54015
      09330-00021

      Tech Tips

      Part number of installation bolt for SST (crankshaft pulley holding tool): 91551-80650 (quantity: 2)

    2. A01W5J0E09
      Text in Illustration
      *1 Crankshaft Pulley Set Bolt
      *a Hold
      *b Turn

      Using SST and the crankshaft pulley set bolt, remove the crankshaft pulley and crankshaft pulley set bolt.

      SST
      09950-50013   ( 09951-05010, 09952-05010, 09953-05020, 09954-05011 )

      Tech Tips

      Apply lubricant to the threads and end of SST.

  15. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A01W0AJ

      Remove the 17 bolts, 3 seal washers, cylinder head cover sub-assembly and cylinder head cover gasket.

      Text in Illustration
      B001O8N Bolt
      B001OAO Bolt with Seal Washer
    2. A01W2SYE02
      Text in Illustration
      *1 Camshaft Bearing Cap Oil Hole Gasket
      *a Gasket

      Remove the camshaft bearing cap oil hole gasket from the No. 1 camshaft bearing cap.

    3. Remove the gasket from the No. 2 camshaft bearing cap.

  16. REMOVE CASE SEPARATOR


    1. A01W58W

      Remove the 2 bolts and case separator from the cylinder head cover case sub-assembly.

    2. A01W28W

      Remove the oil separator gasket from the case separator.

    3. A01W471E02
      Text in Illustration
      *a O-ring

      Remove the O-ring from the case separator.

  17. REMOVE SPARK PLUG TUBE GASKET


    1. A01W5MCE02
      Text in Illustration
      *a Protective Tape

      Using a screwdriver, pry out 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

      Tape the screwdriver tip before use.

  18. REMOVE CAMSHAFT TIMING OIL CONTROL SOLENOID ASSEMBLY

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  19. REMOVE TIMING CHAIN COVER PLATE

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  20. REMOVE ENGINE MOUNTING BRACKET RH

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  21. REMOVE TIMING CHAIN COVER ASSEMBLY

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  22. REMOVE TIMING CHAIN COVER OIL SEAL

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  23. SET NO. 1 CYLINDER TO TDC/COMPRESSION


    1. Temporarily install the crankshaft pulley set bolt.

      A01W1D3E02
      Text in Illustration
      *1 Crankshaft Pulley Key - -
      *a Approximately 7° *b Approximately 32°
      *c Timing Mark - -

    2. Rotate the crankshaft clockwise and align the crankshaft pulley key as shown in the illustration.

    3. Check that the timing marks on the camshaft timing exhaust gear assembly and camshaft timing gear assembly are as shown in the illustration.

      Tech Tips

      "A" is not a timing mark.

    4. Remove the crankshaft pulley set bolt.

  24. REMOVE TIMING CHAIN GUIDE


    1. A01W5B5

      Remove the bolt and timing chain guide.

  25. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY


    1. A01W5QLE02
      Text in Illustration
      *a Stopper Plate
      *b Plunger

      Allow the plunger to extend slightly, and then turn the stopper plate counterclockwise to release the lock. Once the lock is released, push the plunger into the No. 1 chain tensioner assembly.

    2. A01W0KEE02
      Text in Illustration
      *a Pin

      Turn the stopper plate clockwise to set the lock, and insert a pin into the stopper plate hole.

    3. A01W00K

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

  26. REMOVE CHAIN TENSIONER SLIPPER


    1. A01W1D5

      Remove the bolt and chain tensioner slipper.

  27. REMOVE CHAIN SUB-ASSEMBLY


    1. Remove the chain sub-assembly.

  28. REMOVE NO. 1 CHAIN VIBRATION DAMPER


    1. A01W2T8

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

  29. REMOVE CRANKSHAFT TIMING SPROCKET


    1. A01W144

      Remove the crankshaft timing sprocket from the crankshaft.

  30. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY


    1. A01W3MLE01
      Text in Illustration
      *a Hold
      B001O8N Turn

      Using a wrench to hold the hexagonal portion of the camshaft, remove the camshaft timing gear bolt and camshaft timing gear assembly.

      Note


      • Be careful not to damage the cylinder head sub-assembly or spark plug tube with the wrench.

      • Do not disassemble the camshaft timing gear assembly.

  31. REMOVE CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY


    1. A01W5ISE01
      Text in Illustration
      *a Hold
      B001O8N Turn

      Using a wrench to hold the hexagonal portion of the No. 2 camshaft, remove the bolt and camshaft timing exhaust gear assembly.

      Note


      • Be careful not to damage the cylinder head sub-assembly or spark plug tube with the wrench.

      • Do not disassemble the camshaft timing exhaust gear assembly.

  32. REMOVE OIL PIPE SUB-ASSEMBLY


    1. A01W080

      Remove the bolt and oil pipe sub-assembly from the No. 4 camshaft bearing cap.

  33. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY


    1. A01W4RNE03

      Uniformly loosen and remove the 20 bolts in the order shown in the illustration.

    2. A01W1VD

      Remove the camshaft housing sub-assembly by prying between the cylinder head sub-assembly and camshaft housing sub-assembly with a screwdriver.

      Note

      Be careful not to damage the contact surfaces of the cylinder head sub-assembly and camshaft housing sub-assembly.

      Tech Tips

      Tape the screwdriver tip before use.

  34. REMOVE CAMSHAFT BEARING CAP


    1. A01W15ZE03

      Remove the 11 bolts in the order shown in the illustration.

    2. Remove the No. 1 camshaft bearing cap, No. 2 camshaft bearing cap, No. 3 camshaft bearing cap and No. 4 camshaft bearing cap.

      Tech Tips

      Arrange the removed parts in the correct order.

  35. REMOVE CAMSHAFT


    1. Remove the camshaft from the camshaft housing sub-assembly.

  36. REMOVE NO. 2 CAMSHAFT


    1. Remove the No. 2 camshaft from the camshaft housing sub-assembly.

  37. REMOVE OIL CONTROL VALVE FILTER


    1. A01W4X1

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

  38. REMOVE NO. 1 CAMSHAFT BEARING


    1. A01W35L

      Remove the No. 1 camshaft bearing from the No. 1 camshaft bearing cap.

  39. REMOVE NO. 2 CAMSHAFT BEARING


    1. A01VZJO

      Remove the No. 2 camshaft bearing from the camshaft housing sub-assembly.

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


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

      Tech Tips

      Arrange the removed parts in the correct order.

  41. REMOVE VALVE LASH ADJUSTER ASSEMBLY


    1. Remove the 16 valve lash adjuster assemblies from the cylinder head sub-assembly.

      Tech Tips

      Arrange the removed parts in the correct order.

  42. REMOVE VALVE STEM CAP


    1. Remove the 16 valve stem caps from the cylinder head sub-assembly.

      Tech Tips

      Arrange the removed parts in the correct order.

  43. REMOVE CAMSHAFT HOUSING STUD BOLT

    Note

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

  44. REMOVE CAMSHAFT BEARING CAP SETTING RING PIN

    Note

    It is not necessary to remove the camshaft bearing cap setting ring pin unless it is being replaced.

  45. REMOVE CAMSHAFT HOUSING STRAIGHT PIN

    Note

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

  46. REMOVE CYLINDER HEAD SUB-ASSEMBLY

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  47. REMOVE CYLINDER HEAD GASKET

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  48. REMOVE CYLINDER BLOCK WATER JACKET SPACER


    1. A01VZST

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

      Note

      Be sure to remove the cylinder block water jacket spacer. If it is not removed, it may fall and become damaged when the cylinder block sub-assembly is inverted.

  49. REMOVE OIL FILTER CAP ASSEMBLY

    Click here

  50. REMOVE OIL PAN DRAIN PLUG


    1. Remove the oil pan drain plug and gasket from the oil pan sub-assembly.

  51. REMOVE OIL PAN SUB-ASSEMBLY


    1. A01VZ7WE05
      Text in Illustration
      *A Type A
      *B Type B
      B001O8N Bolt
      B001OAO Nut

      Remove the 11 bolts and 2 nuts.

    2. A01W2RA

      Insert the blade of an oil pan seal cutter between the oil pan sub-assembly and stiffening crankcase assembly, cut through the applied sealer and remove the oil pan sub-assembly.

      Note


      • Be careful not to damage the stiffening crankcase assembly contact surface of the oil pan sub-assembly.

      • Be careful not to damage the oil pan sub-assembly flange.

  52. REMOVE OIL STRAINER SUB-ASSEMBLY


    1. A01W1O1

      Remove the 3 bolts, oil strainer sub-assembly and gasket.

  53. REMOVE ENGINE OIL LEVEL SENSOR

    Click here

  54. REMOVE OIL LEVEL SENSOR BRACKET


    1. A01W4VJ

      Remove the 2 bolts and oil level sensor bracket from the stiffening crankcase assembly.

  55. REMOVE NO. 1 OIL PAN BAFFLE PLATE


    1. A01W0L1

      Remove the clamp from the No. 1 oil pan baffle plate.

    2. Remove the 4 bolts and No. 1 oil pan baffle plate.

  56. INSPECT CRANKSHAFT BACKLASH


    1. A01W59Y

      Using a dial indicator, measure the backlash of the crankshaft and balance shaft as shown in the illustration.

      Standard Backlash
      0.05 to 0.20 mm (0.00197 to 0.00787 in.)
      Maximum Backlash
      0.20 mm (0.00787 in.)

      If the backlash is more than the maximum, replace the engine balancer assembly.

  57. REMOVE ENGINE BALANCER ASSEMBLY


    1. A01W2RT

      Remove the 7 bolts and engine balancer assembly from the stiffening crankcase assembly.

      Note

      Do not disassemble the engine balancer assembly.

  58. INSPECT NO. 1 BALANCE SHAFT THRUST CLEARANCE

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  59. INSPECT NO. 2 BALANCE SHAFT THRUST CLEARANCE

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  60. REMOVE STIFFENING CRANKCASE ASSEMBLY


    1. A01W02C

      Remove the 7 bolts.

    2. A01W52SE01
      Text in Illustration
      *a LH Side
      *b RH Side

      Using a screwdriver, remove the stiffening crankcase assembly by prying between the stiffening crankcase assembly and cylinder block sub-assembly at the places shown in the illustration.

      Note

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

      Tech Tips

      Tape the screwdriver tip before use.

  61. REMOVE OIL FILTER BRACKET CLIP


    1. A01W0EL

      Remove the oil filter bracket clip from the stiffening crankcase assembly.

  62. REMOVE STIFFENING CRANKCASE STUD BOLT

    Note

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

  63. REMOVE STIFFENING CRANKCASE RING PIN

    Note

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

  64. REMOVE REAR ENGINE OIL SEAL


    1. Remove the rear engine oil seal from the cylinder block sub-assembly.