ENGINE UNIT DISASSEMBLY

CAUTION / NOTICE / HINT

Note

This procedure includes the installation of small-head bolts. Refer to Small-Head Bolts of Basic Repair Hint to identify the small-head bolts.

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PROCEDURE


  1. REMOVE SPARK PLUG

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  2. REMOVE KNOCK CONTROL SENSOR

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  3. REMOVE ENGINE COOLANT TEMPERATURE SENSOR

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  4. REMOVE ENGINE OIL TEMPERATURE SENSOR

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  5. REMOVE OIL PRESSURE SENSOR (OIL PRESSURE SENDER GAUGE ASSEMBLY)

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  6. REMOVE OIL PRESSURE CONTROL VALVE ASSEMBLY

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  7. REMOVE CAMSHAFT POSITION SENSOR (for Intake Side)

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  8. REMOVE CAMSHAFT POSITION SENSOR (for Exhaust Side)

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  9. REMOVE CAM TIMING OIL CONTROL SOLENOID ASSEMBLY

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  10. REMOVE CAM TIMING CONTROL MOTOR WITH EDU ASSEMBLY

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  11. REMOVE CAM TIMING CONTROL MOTOR O-RING

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  12. REMOVE OIL FILLER CAP SUB-ASSEMBLY


    1. B00701R

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

  13. REMOVE OIL FILLER CAP GASKET


    1. B006WXB

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

  14. REMOVE CRANKSHAFT POSITION SENSOR

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

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  16. REMOVE VACUUM PUMP ASSEMBLY

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  17. REMOVE CRANKSHAFT PULLEY ASSEMBLY


    1. B006XHRC01
      *a Hold
      *b Turn

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

      SST
      09213-54015
      09330-00021
    2. B0071KAC01
      *1 Crankshaft Pulley Bolt
      *a Hold
      *b Turn

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

      SST
      09950-50013   ( 09951-05010, 09952-05010, 09953-05020, 09954-05070, 09957-04010 )

      Tech Tips

      Apply lubricant to the threads and end of SST.

  18. REMOVE WATER OUTLET


    1. B0070Z0

      Using an 8 mm socket wrench, remove the 3 bolts, water outlet and water outlet gasket from the cylinder head sub-assembly.

  19. REMOVE OUTLET WATER BY-PASS SUB-ASSEMBLY


    1. B006ZR0

      Using an 8 mm socket wrench, remove the 3 bolts, outlet water by-pass sub-assembly and outlet water pipe gasket from the cylinder head sub-assembly.

  20. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY


    1. B0070F4

      Using an 8 mm socket wrench, remove the 16 bolts and cylinder head cover sub-assembly from the camshaft housing sub-assembly.

    2. B006Z9K

      Remove the 7 cylinder head cover gaskets from the cylinder head cover sub-assembly.

    3. B0070YX

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

  21. REMOVE SPARK PLUG TUBE GASKET


    1. B006YINC01
      *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.

  22. REMOVE ENGINE MOUNTING BRACKET RH


    1. B00710H

      Remove the 3 bolts and engine mounting bracket RH from the No. 2 timing gear cover assembly.

  23. REMOVE ENGINE MOUNTING INSULATOR RH


    1. B006ZC3

      Remove the engine mounting insulator RH from the engine mounting bracket RH.

  24. REMOVE STRAIGHT SCREW PLUG


    1. B0071P6

      Using a 10 mm hexagon wrench, remove the straight screw plug from the No. 2 timing gear cover assembly.

  25. REMOVE NO. 2 TIMING GEAR COVER ASSEMBLY


    1. B006ZXE

      Remove the 20 bolts.

    2. Remove the No. 2 timing gear cover assembly from the timing chain cover assembly by prying the No. 2 timing gear cover assembly with a screwdriver with its tip wrapped with protective tape.

      B006WTAC01
      *a Protective Tape - -

      Note

      Be careful not to damage the contact surfaces of the No. 2 timing gear cover assembly and timing chain cover assembly.

  26. REMOVE TIMING CHAIN COVER OIL SEAL


    1. B0070CCC01
      *a Protective Tape
      *b Wooden Block

      Using a screwdriver and wooden block, pry out the timing chain cover oil seal.

      Note

      Do not damage the surface of the timing chain cover oil seal press fit hole.

      Tech Tips

      Tape the screwdriver tip before use.

  27. SET NO. 1 CYLINDER TO TDC (COMPRESSION)


    1. Temporarily install the crankshaft pulley bolt.

      B0071OXC01
      *1 Crankshaft Timing Gear Key - -
      *a Approximately 11.4° *b Approximately 23.7°
      *c Approximately 24.3° *d Timing Mark

    2. Rotate the crankshaft clockwise and align the crankshaft timing gear 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.

    4. Remove the crankshaft pulley bolt.

      Tech Tips

      As the No. 2 camshaft may rotate counterclockwise strongly when the crankshaft pulley bolt is removed, use a wrench to hold the hexagonal portion of the No. 2 camshaft.

  28. REMOVE OIL PUMP DRIVE CHAIN SUB-ASSEMBLY


    1. Temporarily install the crankshaft pulley assembly with the crankshaft pulley bolt.

    2. B0070R5C01
      *a Bolt

      While holding the crankshaft pulley assembly with SST, remove the bolt.

      SST
      09213-54015
      09330-00021

    3. Remove SST, the crankshaft pulley bolt and crankshaft pulley assembly.

    4. B006XOKC01
      *1 Chain Tensioner Plate
      *2 Chain Damper Spring

      Remove the chain tensioner plate and chain damper spring.

    5. B006Y3IC01
      *1 Oil Pump Drive Chain Sub-assembly
      *2 Oil Pump Drive Sprocket
      *3 Oil Pump Drive Shaft Sprocket

      Remove the oil pump drive sprocket, oil pump drive shaft sprocket and oil pump drive chain sub-assembly.

  29. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY


    1. B006WVH

      Push the plunger into the No. 1 chain tensioner assembly.

    2. B006Y8RC01
      *a Pin
      *b Plunger Groove

      Fully insert the plunger, align the No. 1 chain tensioner assembly body hole with the plunger groove and insert a pin.

    3. B0070AG

      Using an 8 mm socket wrench, remove the bolt.

    4. Remove the nut and No. 1 chain tensioner assembly.

  30. REMOVE CHAIN TENSIONER SLIPPER


    1. B006ZFB

      Remove the bolt and chain tensioner slipper.

  31. REMOVE CHAIN SUB-ASSEMBLY


    1. B0070P5

      Remove the crankshaft timing sprocket and chain sub-assembly.

  32. REMOVE NO. 1 CHAIN VIBRATION DAMPER


    1. B006YV3

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

  33. REMOVE CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY


    1. B006ZW8

      Using a wrench, hold the hexagonal portion of the No. 2 camshaft.

      Note

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

    2. Using a 5 mm hexagon socket wrench, remove the 3 bolts.

    3. B006Z36C01
      *1 Camshaft Timing Exhaust Gear Assembly
      *2 Camshaft Timing Oil Control Valve Assembly (Exhaust Camshaft Timing Gear Bolt Assembly)

      Remove the camshaft timing exhaust gear assembly and camshaft timing oil control valve assembly (exhaust camshaft timing gear bolt assembly).

  34. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY


    1. B0070CXC01
      *a Hold
      *b Turn

      Using a wrench, hold the hexagonal portion of the camshaft.

      Note


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

      • Do not disassemble the camshaft timing gear assembly.

    2. Using a 10 mm bi-hexagonal wrench, remove the bolt and camshaft timing gear assembly from the camshaft.

  35. REMOVE TIMING CHAIN COVER ASSEMBLY

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  36. REMOVE OIL NOZZLE VALVE SUB-ASSEMBLY


    1. B0071V6

      Remove the oil nozzle valve sub-assembly from the cylinder block sub-assembly.

  37. REMOVE CRANKSHAFT TIMING GEAR KEY


    1. B006XBDC01
      *a Protective Tape

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

      Tech Tips

      Tape the screwdriver tip before use.

  38. REMOVE FUEL PUMP LIFTER GUIDE


    1. B0070FN

      Using an 8 mm socket wrench, remove the 2 bolts and fuel pump lifter guide from the No. 4 camshaft bearing cap.

  39. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY


    1. B006YVGN01

      Uniformly loosen and remove the 18 bolts in the order shown in the illustration.

    2. B006ZQ0

      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.

  40. REMOVE CAMSHAFT BEARING CAP


    1. B006Y8AC01
      *1 No. 1 Camshaft Bearing Cap
      *2 No. 2 Camshaft Bearing Cap
      *3 No. 3 Camshaft Bearing Cap
      *4 No. 4 Camshaft Bearing Cap

      Remove the 8 bolts in the order shown in the illustration.

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

      Tech Tips

      Arrange the removed parts in such a way that they can be reinstalled to their original locations.

  41. REMOVE CAMSHAFT

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  42. REMOVE NO. 2 CAMSHAFT

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  43. REMOVE CAMSHAFT BEARING CAP SETTING RING PIN

    Note

    It is not necessary to remove the camshaft bearing cap setting ring pins unless they are being replaced.


    1. B00717Y

      Remove the 10 camshaft bearing cap setting ring pins from the camshaft housing sub-assembly.

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


    1. B0071VQ

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

      Tech Tips

      Arrange the removed parts in such a way that they can be reinstalled to their original locations.

  45. REMOVE VALVE LASH ADJUSTER ASSEMBLY


    1. B006Z27

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

      Tech Tips

      Arrange the removed parts in such a way that they can be reinstalled to their original locations.

  46. REMOVE VALVE STEM CAP


    1. B0070GJ

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

      Tech Tips

      Arrange the removed parts in such a way that they can be reinstalled to their original locations.

  47. REMOVE WATER SEAL PLATE


    1. B006YL9

      Using an 8 mm socket wrench, remove the 2 bolts, water seal plate and gasket from the cylinder head sub-assembly.

  48. REMOVE CYLINDER HEAD SUB-ASSEMBLY


    1. B0071Q7C03
      B006ZY0 Front of Engine

      Using a 12 mm socket wrench, uniformly loosen the 10 cylinder head set bolts in the order shown in the illustration. Remove the 10 cylinder head set bolts and 10 plate washers.

      Note


      • Be careful not to drop the plate washers into the cylinder head sub-assembly.

      • Warpage or cracking of the cylinder head sub-assembly may result from removing the cylinder head set bolts in the incorrect order.

      Tech Tips

      Arrange the removed parts in such a way that they can be reinstalled to their original locations.

    2. Remove the cylinder head sub-assembly from the cylinder block sub-assembly.

  49. REMOVE CYLINDER HEAD GASKET

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  50. REMOVE CYLINDER BLOCK WATER JACKET SPACER


    1. B006YU3

      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.

  51. REMOVE OIL FILTER SUB-ASSEMBLY

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  52. REMOVE OIL FILTER UNION

    B006ZGW

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

  53. REMOVE OIL PAN DRAIN PLUG


    1. Remove the oil pan drain plug and gasket from the No. 2 oil pan sub-assembly.

  54. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY


    1. B0071ICC01
      *a Nut

      Remove the 11 bolts and 2 nuts.

    2. B0070N3

      Insert the blade of an oil pan seal cutter between the No. 2 oil pan sub-assembly and stiffening crankcase assembly, cut through the applied sealer and remove the No. 2 oil pan sub-assembly.

      Note


      • Be careful not to damage the contact surfaces of the stiffening crankcase assembly and No. 2 oil pan sub-assembly.

      • Be careful not to damage the No. 2 oil pan sub-assembly flange.

  55. REMOVE OIL STRAINER SUB-ASSEMBLY


    1. B006ZPT

      Using an 8 mm socket wrench, remove the bolt, oil strainer sub-assembly and oil strainer gasket.

  56. REMOVE ENGINE OIL LEVEL SENSOR

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  57. REMOVE OIL PUMP BRACKET


    1. B0070OA

      Remove the 2 bolts and oil pump bracket.

  58. INSPECT CRANKSHAFT BACKLASH


    1. B006XA3

      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.

  59. REMOVE ENGINE BALANCER ASSEMBLY


    1. B006ZXY

      Remove the 6 bolts and engine balancer assembly from the stiffening crankcase assembly.

      Note

      Do not disassemble the engine balancer assembly.

  60. REMOVE OIL PUMP ASSEMBLY

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  61. REMOVE STIFFENING CRANKCASE ASSEMBLY


    1. B0071B0

      Remove the 7 bolts.

    2. B006XH4

      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.

  62. REMOVE STRAIGHT SCREW PLUG


    1. B006Z6N

      Using a 10 mm hexagon socket wrench, remove the 3 straight screw plugs and 3 gaskets from the stiffening crankcase assembly.

  63. REMOVE WIRE HARNESS CLAMP BRACKET


    1. B0071RP

      Remove the bolt and wire harness clamp bracket from the stiffening crankcase assembly.

  64. REMOVE STUD BOLT

    Note

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

  65. REMOVE RING PIN

    Note

    It is not necessary to remove the ring pins unless they are being replaced.

  66. REMOVE STRAIGHT PIN

    Note

    It is not necessary to remove the straight pins unless they are being replaced.

  67. REMOVE REAR ENGINE OIL SEAL


    1. B006Z3A

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