ENGINE UNIT DISASSEMBLY

PROCEDURE


  1. REMOVE ENGINE COVER JOINT


    1. B004L27

      Remove the 3 engine cover joints.

  2. REMOVE SPARK PLUG

    Click here

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

    Click here

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

    Click here

  5. REMOVE CAMSHAFT POSITION SENSOR (for Exhaust Side)

    Click here

  6. REMOVE CAMSHAFT POSITION SENSOR (for Intake Side)

    Click here

  7. REMOVE OIL FILLER CAP SUB-ASSEMBLY


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

  8. REMOVE OIL FILLER CAP GASKET


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

  9. REMOVE CRANKSHAFT POSITION SENSOR

    Click here

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

    Click here

  11. REMOVE VENTILATION CASE SUB-ASSEMBLY


    1. B004MW6C05
      *a Nut

      Remove the 8 bolts and 2 nuts.

    2. B004IIB

      Using a screwdriver with its tip wrapped with protective tape, remove the ventilation case sub-assembly by prying between the ventilation case sub-assembly and cylinder block sub-assembly.

      Note

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

      Tech Tips

      Tape the screwdriver tip before use.

  12. REMOVE SEPARATOR CASE


    1. B004L9T

      Remove the 2 bolts, separator case and gasket from the ventilation case sub-assembly.

  13. REMOVE NO. 1 WATER BY-PASS PIPE


    1. B004KEC

      Remove the bolt, 2 nuts, No. 1 water by-pass pipe and gasket.

  14. REMOVE WATER INLET

    Click here

  15. REMOVE THERMOSTAT

    Click here

  16. REMOVE OIL COOLER ASSEMBLY (w/ Oil Cooler)

    Click here

  17. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY


    1. B004N6E

      Remove the bolt and V-ribbed belt tensioner assembly.

  18. REMOVE WIRE HARNESS CLAMP BRACKET


    1. B004NBP

      Remove the bolt and wire harness clamp bracket.

  19. REMOVE ENGINE WATER PUMP ASSEMBLY

    Click here

  20. REMOVE WATER INLET HOUSING


    1. B004O1KC04
      *a Bolt
      *b Nut

      Remove the 4 bolts, nut and water inlet housing from the cylinder block sub-assembly.

    2. B004K7G

      Remove the gasket from the cylinder block sub-assembly.

    3. B004JYW

      w/o Oil Cooler:


      1. Using an E6 "TORX" socket wrench, remove the 4 stud bolts from the water inlet housing.

        Note

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

    4. w/ Oil Cooler:


      1. Using an E6 "TORX" socket wrench, remove the 5 stud bolts from the water inlet housing.

        B004IXE

        Note

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

  21. REMOVE CRANKSHAFT PULLEY

    Click here

  22. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY


    1. B004KA3C07
      *a Seal Washer

      Remove the 16 bolts, 3 seal washers, cylinder head cover sub-assembly and cylinder head cover gasket.

    2. B004HTEC01
      *1 Camshaft Bearing Cap Oil Hole Gasket
      *a Gasket

      Remove the 2 camshaft bearing cap oil hole gaskets from the No. 1 camshaft bearing cap.

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

  23. REMOVE SPARK PLUG TUBE GASKET


    1. B004IZH

      Using a screwdriver, pry out the 4 spark plug tube gaskets.

      Note

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

      Tech Tips

      Tape the screwdriver tip before use.

  24. REMOVE ENGINE MOUNTING BRACKET RH

    Click here

  25. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY

    Click here

  26. REMOVE OIL PUMP RELIEF VALVE PLUG


    1. B004K73

      Using a 14 mm hexagon wrench, remove the oil pump relief valve plug and gasket.

  27. REMOVE TIMING CHAIN COVER PLATE

    Click here

  28. REMOVE TIMING CHAIN COVER OIL SEAL

    Click here

  29. SET NO. 1 CYLINDER TO TDC/COMPRESSION


    1. Temporarily install the crankshaft pulley bolt.

      B004J9DC18
      *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 bolt.

  30. REMOVE TIMING CHAIN GUIDE

    Click here

  31. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY

    Click here

  32. REMOVE CHAIN TENSIONER SLIPPER

    Click here

  33. REMOVE CHAIN SUB-ASSEMBLY

    Click here

  34. REMOVE NO. 1 CHAIN VIBRATION DAMPER

    Click here

  35. REMOVE CRANKSHAFT TIMING SPROCKET


    1. B004IUT

      Remove the crankshaft timing sprocket from the crankshaft.

  36. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY

    Click here

  37. REMOVE CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY

    Click here

  38. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY

    Click here

  39. REMOVE CAMSHAFT BEARING CAP

    Click here

  40. REMOVE OIL CONTROL VALVE FILTER


    1. B004MZQ

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

  41. REMOVE CAMSHAFT

    Click here

  42. REMOVE NO. 2 CAMSHAFT

    Click here

  43. REMOVE NO. 1 CAMSHAFT BEARING


    1. B004NT2

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

  44. REMOVE NO. 2 CAMSHAFT BEARING


    1. B004MKU

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

  45. 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. B004IV7

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

  46. REMOVE CAMSHAFT HOUSING STRAIGHT PIN

    Note

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


    1. B004OBV

      Remove the 2 camshaft housing straight pins from the camshaft housing sub-assembly.

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

    Click here

  48. REMOVE VALVE LASH ADJUSTER ASSEMBLY

    Click here

  49. REMOVE VALVE STEM CAP

    Click here

  50. REMOVE CYLINDER HEAD SUB-ASSEMBLY

    Click here

  51. REMOVE CYLINDER HEAD GASKET

    Click here

  52. REMOVE CYLINDER BLOCK WATER JACKET SPACER


    1. B004O3Z

      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.

  53. REMOVE OIL FILTER CAP ASSEMBLY

    Click here

  54. REMOVE OIL PAN DRAIN PLUG


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

  55. REMOVE OIL PAN SUB-ASSEMBLY


    1. B004IMHC18
      *a Nut

      Remove the 11 bolts and 2 nuts.

    2. B0070N3

      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 contact surfaces of the stiffening crankcase assembly and oil pan sub-assembly.

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

  56. REMOVE OIL STRAINER SUB-ASSEMBLY


    1. B004LPQ

      Remove the 3 bolts and oil strainer sub-assembly.

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

  57. REMOVE NO. 1 OIL PAN BAFFLE PLATE


    1. B004K4E

      Remove the 5 bolts and No. 1 oil pan baffle plate.

  58. INSPECT CRANKSHAFT BACKLASH


    1. B004HHY

      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. B004KO5

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

      Note

      Do not disassemble the engine balancer assembly.

  60. REMOVE STIFFENING CRANKCASE ASSEMBLY


    1. B004MHY

      Remove the 7 bolts.

    2. B004HMMC03
      *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 STIFFENING CRANKCASE RING PIN

    Note

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


    1. B004JHP

      Remove the 2 stiffening crankcase ring pins from the stiffening crankcase assembly.

  62. REMOVE STUD BOLT

    Note

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


    1. B004J03

      Using an E6 "TORX" socket wrench, remove the 3 stud bolts from the cylinder head cover sub-assembly.

    2. B004LFZ

      Using an E8 "TORX" socket wrench, remove the stud bolt from the camshaft housing sub-assembly.

    3. B004JD0

      Using E5 and E8 "TORX" socket wrenches, remove the 3 stud bolts from the stiffening crankcase assembly.

    4. B004MFU

      Using an E10 "TORX" socket wrench, remove the stud bolt from the cylinder block sub-assembly.

  63. REMOVE REAR ENGINE OIL SEAL


    1. B004KKH

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