ENGINE UNIT DISASSEMBLY

PROCEDURE


  1. REMOVE SPARK PLUG

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  2. REMOVE CAMSHAFT POSITION SENSOR

    A01VFIV

    1. Remove the bolt and camshaft position sensor.

  3. REMOVE ENGINE COOLANT TEMPERATURE SENSOR

    A01VHG1E02
    Text in Illustration
    *a 19 mm Deep Socket Wrench

    1. Using a 19 mm deep socket wrench, remove the engine coolant temperature sensor.

    2. Remove the gasket from the engine coolant temperature sensor.

  4. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY

    A01VH5B

    1. Remove the bolt and camshaft timing oil control valve assembly.

  5. REMOVE CRANKSHAFT POSITION SENSOR

    A01VEGR

    1. Remove the bolt and crankshaft position sensor.

  6. REMOVE KNOCK SENSOR

    A01VKAP

    1. Remove the bolt and knock sensor.

  7. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY

    A01VLG9E02
    Text in Illustration
    *a 24 mm Deep Socket Wrench

    1. Using a 24 mm deep socket wrench, remove the oil pressure switch assembly.

  8. REMOVE OIL CONTROL VALVE FILTER

    A01VKUXE02
    Text in Illustration
    *a 8 mm Socket Hexagon Wrench

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

    2. A01VGYVE02
      Text in Illustration
      *1 Oil Control Valve Filter
      *2 Gasket
      *3 Head Taper Screw Plug

      Remove the oil control valve filter and gasket.

  9. REMOVE OIL FILLER CAP SUB-ASSEMBLY

    A01VEQH

    1. Remove the oil filler cap.

    2. Using a screwdriver, remove the oil filler cap gasket from the oil filler cap sub-assembly.

  10. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY

    A01VM5Q

    1. Remove the 13 bolts, 2 nuts and cylinder head cover sub-assembly.

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

  11. REMOVE VENTILATION VALVE SUB-ASSEMBLY

    A01VJVPE03
    Text in Illustration
    *1 Ventilation Valve Sub-assembly
    *2 Grommet

    1. Remove the ventilation valve sub-assembly.

    2. Remove the grommet.

  12. REMOVE OIL PAN DRAIN PLUG

    A01VDLF

    1. Remove the oil pan drain plug.

    2. Remove the oil pan drain plug gasket.

  13. REMOVE OIL PAN SUB-ASSEMBLY (for TMC Made)

    A01VE2E

    1. Remove the 12 bolts and 3 nuts.

    2. A01VJNUE04
      Text in Illustration
      *a Oil Pan Seal Cutter

      Using an oil pan seal cutter, remove the oil pan sub-assembly.

      Note

      Be careful not to damage the contact surfaces of the oil pan sub-assembly.

  14. REMOVE OIL PAN SUB-ASSEMBLY (for TMMF Made)

    A01VDR7

    1. Remove the 13 bolts and 2 nuts.

    2. A01VJNUE05
      Text in Illustration
      *a Oil Pan Seal Cutter

      Using an oil pan seal cutter, remove the oil pan sub-assembly.

      Note

      Be careful not to damage the contact surfaces of the oil pan sub-assembly.

  15. REMOVE OIL STRAINER SUB-ASSEMBLY

    A01VFUA

    1. Remove the 3 bolts and oil strainer sub-assembly.

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

  16. REMOVE WATER INLET

    A01VEP8

    1. Remove the 2 bolts and water inlet.

  17. REMOVE THERMOSTAT


    1. Remove the thermostat with water outlet gasket from the water inlet.

    2. A01VLMJ

      Remove the water outlet gasket from the thermostat.

  18. DISCONNECT NO. 1 WATER BY-PASS PIPE

    A01VFIE

    1. Remove the 3 bolts to separate the No. 1 water by-pass pipe from the cylinder head sub-assembly and cylinder block, then remove the water by-pass pipe gasket.

    2. A01VFNH

      Slide the hose clip and disconnect the water by-pass hose with the No. 1 water by-pass pipe from the timing chain cover sub-assembly.

  19. DISCONNECT WATER BY-PASS HOSE

    A01VHIF

    1. Slide the hose clip and disconnect the water by-pass hose from the No. 1 water by-pass pipe.

  20. REMOVE ENGINE WATER PUMP ASSEMBLY

    A01VHRZ

    1. Remove the 5 bolts and remove the engine water pump assembly.

    2. A01VGJS

      Remove the water pump gasket.

  21. REMOVE OIL FILTER SUB-ASSEMBLY

    A01VKCLE01

    1. Using SST, remove the oil filter sub-assembly.

      SST
      09228-06501

  22. REMOVE OIL FILTER BRACKET

    A01VFPG

    1. Remove the 3 bolts and oil filter bracket.

    2. A01VLKP

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

  23. REMOVE TIGHT PLUG

    A01VI00E05
    Text in Illustration
    *a 8 mm Socket Hexagon Wrench

    1. Using an 8 mm socket hexagon wrench, remove the tight plug.

  24. SET NO. 1 CYLINDER TO TDC/EXHAUST

    A01VKHLE01
    Text in Illustration
    *a Timing Mark

    1. Turn the crankshaft pulley clockwise to align the timing mark on the pulley with the timing mark of the timing chain cover sub-assembly.

    2. A01VECAE02
      Text in Illustration
      *a Timing Mark

      Make sure that the timing mark of the camshaft timing gear is at the top.

  25. REMOVE CRANKSHAFT PULLEY

    A01VE1HE01
    Text in Illustration
    *a Hold
    *b Turn

    1. Using SST, loosen the crankshaft pulley bolt.

      SST
      09960-10010   ( 09962-01000, 09963-01000 )
    2. A01VGABE01
      Text in Illustration
      *a Hold
      *b Turn

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

      SST
      09950-40011   ( 09951-04010, 09953-04030, 09958-04011, 09955-04011, 09954-04010, 09952-04010 )

  26. REMOVE DRAIN PLUG

    A01VFMT

    1. Remove the drain plug and gasket.

  27. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY


    1. A01VJKU

      Remove the 11 bolts from the timing chain cover sub-assembly.

    2. A01VIZTE04
      Text in Illustration
      *a Protective Tape

      Using a screwdriver with its tip wrapped in protective tape, remove the timing chain cover sub-assembly by prying between the cylinder head sub-assembly and cylinder block.

      Note

      Do not damage the contact surfaces of the timing chain cover sub-assembly, cylinder head sub-assembly or cylinder block.

    3. A01VGQY

      Remove the oil pump gasket from the cylinder block.

  28. REMOVE STUD BOLT (for TMC Made)


    1. A01VGHZ

      Remove the 2 studs bolt from the timing chain cover sub-assembly.

  29. REMOVE STUD BOLT (for TMMF Made)

    A01VLC7

    1. Remove the stud bolt from the timing chain cover sub-assembly.

  30. REMOVE TIMING CHAIN COVER OIL SEAL

    A01VGV6E05
    Text in Illustration
    *a Protective Tape
    *b Wooden Block

    1. Using a screwdriver with its tip wrapped in protective tape and a wooden block, remove the timing chain cover oil seal from the timing chain cover sub-assembly.

  31. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY

    A01VK7JE03

    1. Turn the stopper plate of the No. 1 chain tensioner assembly clockwise and push in the plunger with the lock released.

      Text in Illustration
      *a Stopper Plate
    2. A01VGVQE03
      Text in Illustration
      *a Hexagon Wrench
      *b Stopper Plate

      Insert a hexagon wrench into the hole in the stopper plate to lock with the plunger pushed in.

    3. A01VGT6

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

  32. REMOVE TIMING CHAIN TENSION ARM

    A01VKPN

    1. Remove the bolt and timing chain tension arm.

  33. REMOVE CHAIN SUB-ASSEMBLY

  34. REMOVE TIMING CHAIN GUIDE

    A01VJX1

    1. Remove the 2 bolts and timing chain guide.

  35. REMOVE CRANKSHAFT TIMING SPROCKET

    A01VI5I

    1. Remove the crankshaft timing sprocket from the crankshaft.

  36. REMOVE CRANKSHAFT STRAIGHT PIN

    A01VDUV

    1. Remove the crankshaft straight pin from the crankshaft.

  37. REMOVE CAMSHAFT TIMING SPROCKET ASSEMBLY

    A01VJOPE02

    1. Rotate the crankshaft 90° clockwise.

      Note

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

    2. A01VICSE01
      Text in Illustration
      *a Hold
      *b Turn

      Remove the bolt from the camshaft timing sprocket assembly while holding the hexagonal portion of the camshaft.

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

  38. REMOVE CAMSHAFT TIMING GEAR

    A01VJ6GE01
    Text in Illustration
    *a Hold
    *b Turn

    1. Remove the bolt from the gear while holding the hexagonal portion of the No. 2 camshaft.

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

  39. REMOVE CAMSHAFTS

    A01VE2QE04

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

      Text in Illustration
      *1 No. 1 Camshaft Bearing Cap
      *2 No. 2 Camshaft Bearing Cap

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

    3. A01VJYH

      Remove the camshaft and No. 2 camshaft.

  40. REMOVE VENTILATION BAFFLE PLATE

    A01VEVU

    1. Remove the 6 bolts, 2 nuts and ventilation baffle plate from the cylinder block.

  41. REMOVE ENGINE REAR OIL SEAL RETAINER

    A01VKGH

    1. Remove the 4 bolts and engine rear oil seal retainer from the cylinder block.

    2. A01VKT6

      Remove the stud bolt from the engine rear oil seal retainer.

  42. REMOVE ENGINE REAR OIL SEAL

    A01VELIE01
    Text in Illustration
    *a Protective Tape
    *b Wooden Block

    1. Using a screwdriver with its tip wrapped in protective tape and a wooden block, remove the engine rear oil seal from the engine rear oil seal retainer.

  43. REMOVE VALVE LIFTER

    A01VFZS

    1. Remove the 12 valve lifters.

      Note


      • Record the inscribed mark on the valve lifters for each valve after removing them.

      • Arrange the valve lifters for each cylinder in order.

  44. REMOVE CYLINDER HEAD SUB-ASSEMBLY

    A01VDPAE07

    1. Using several steps, uniformly loosen and remove the 8 cylinder head set bolts and 8 plate washers with an 8 mm bi-hexagon wrench in the sequence shown in the illustration.

      Note


      • Head warpage or cracking could result from removing the cylinder head set bolts in the wrong order.

      • Do not drop the washers into the cylinder head sub-assembly.

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

  45. REMOVE CYLINDER HEAD GASKET

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  46. REMOVE CYLINDER BLOCK WATER JACKET SPACER

    A01VF4M

    1. Remove the cylinder block water jacket spacer from the cylinder block.