ENGINE UNIT DISASSEMBLY

PROCEDURE


  1. REMOVE WATER BY-PASS PIPE


    1. A01VEYO

      Remove the 3 bolts and water by-pass pipe from the cylinder head sub-assembly and timing chain cover sub-assembly.

    2. A01VKX5

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

  2. REMOVE OIL LEVEL DIPSTICK SUB-ASSEMBLY


    1. A01VGTD

      Remove the oil level dipstick sub-assembly from the oil level dipstick guide.

  3. REMOVE OIL LEVEL DIPSTICK GUIDE


    1. A01VE14

      Remove the bolt and oil level dipstick guide from the cylinder head sub-assembly and oil pan sub-assembly.

  4. REMOVE OIL LEVEL DIPSTICK GUIDE O-RING


    1. A01VKF0

      Remove the oil level dipstick guide O-ring from the oil level dipstick guide.

  5. REMOVE SPARK PLUG

    Click here

  6. REMOVE CAMSHAFT POSITION SENSOR


    1. A01VK3M

      Remove the bolt and camshaft position sensor from the cylinder head sub-assembly.

      Note

      If the camshaft position sensor has been struck or dropped, replace it.

  7. REMOVE ENGINE COOLANT TEMPERATURE SENSOR


    1. A01VKRW

      Using a 19 mm union nut wrench, remove the engine coolant temperature sensor and gasket from the cylinder head sub-assembly.

      Note

      If the engine coolant temperature sensor has been struck or dropped, replace it.

  8. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY


    1. A01VHJ8

      Remove the bolt and camshaft timing oil control valve assembly from the cylinder head sub-assembly.

      Note

      If the camshaft timing oil control valve assembly has been struck or dropped, replace it.

  9. REMOVE CAM TIMING OIL CONTROL VALVE O-RING


    1. A01VLWZ

      Remove the cam timing oil control valve O-ring from the camshaft timing oil control valve assembly.

  10. REMOVE CRANKSHAFT POSITION SENSOR


    1. A01VGFD

      Remove the bolt and crankshaft position sensor from the timing chain cover sub-assembly.

      Note

      If the crankshaft position sensor has been struck or dropped, replace it.

  11. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY


    1. A01VLMC

      Using a 24 mm deep socket wrench, remove the engine oil pressure switch assembly from the cylinder block sub-assembly.

      Note

      If the engine oil pressure switch assembly has been struck or dropped, replace it.

  12. REMOVE KNOCK SENSOR


    1. A01VE3A

      Remove the bolt and knock sensor from the cylinder block sub-assembly.

      Note

      If the knock sensor has been struck or dropped, replace it.

  13. REMOVE OIL CONTROL VALVE FILTER


    1. A01VKQ3E01
      Text in Illustration
      *1 Oil Control Valve Filter
      *2 Cylinder Head Screw Plug Gasket
      *3 Head Taper Screw Plug

      Using an 8 mm hexagon socket wrench, remove the head taper screw plug with the oil control valve filter and cylinder head screw plug gasket from the cylinder head sub-assembly.

    2. Remove the oil control valve filter from the head taper screw plug.

  14. REMOVE OIL FILLER CAP SUB-ASSEMBLY


    1. A01VEFF

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

    2. A01VE84

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

  15. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A01VJVV

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

  16. REMOVE CYLINDER HEAD COVER GASKET


    1. A01VEGO

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

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


    1. A01VFZU

      Remove the PCV valve (ventilation valve sub-assembly) from the ventilation system grommet.

  18. REMOVE VENTILATION SYSTEM GROMMET


    1. A01VGDA

      Remove the ventilation system grommet from the cylinder head cover sub-assembly.

  19. REMOVE GROMMET


    1. A01VJ88

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

  20. REMOVE OIL PAN DRAIN PLUG


    1. A01VJHS

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

  21. REMOVE OIL PAN SUB-ASSEMBLY


    1. A01VELF

      Remove the 13 bolts and 2 nuts.

    2. A01VFKFE02
      Text in Illustration
      *a Oil Pan Seal Cutter

      Insert the blade of an oil pan seal cutter between the oil pan sub-assembly and cylinder block sub-assembly. Cut through the applied sealer and remove the oil pan sub-assembly from the cylinder block sub-assembly and timing chain cover sub-assembly.

      Note

      Be careful not to damage the contact surfaces of the oil pan sub-assembly, cylinder block sub-assembly and timing chain cover sub-assembly.

  22. REMOVE NO. 1 OIL PAN BAFFLE PLATE


    1. A01VHU5

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

  23. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY


    1. A01VHGV

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

  24. REMOVE STRAIGHT PIN

    Tech Tips

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


    1. A01VGW6E01
      Text in Illustration
      *a Upper Side

      Remove the 2 straight pins from the oil pan sub-assembly.

  25. REMOVE OIL STRAINER SUB-ASSEMBLY


    1. A01VIKF

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

    2. A01VHLI

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

  26. REMOVE WATER INLET

    Click here

  27. REMOVE THERMOSTAT

  28. REMOVE ENGINE WATER PUMP ASSEMBLY


    1. A01VI97

      Remove the 5 bolts and engine water pump assembly from the timing chain cover sub-assembly.

    2. A01VHJ5

      Remove the water pump gasket from the timing chain cover sub-assembly.

  29. REMOVE OIL FILTER SUB-ASSEMBLY

    Click here

  30. REMOVE OIL FILTER BRACKET


    1. A01VLGX

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

    2. A01VLLG

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

  31. SET NO. 1 CYLINDER TO TDC/EXHAUST


    1. A01VLO1E02
      Text in Illustration
      *a Timing Mark

      Turn the crankshaft pulley clockwise to align the timing mark of the crankshaft pulley with the timing mark of the timing chain cover sub-assembly (set the No. 1 piston to TDC/exhaust).

    2. A01VJ2SE01
      Text in Illustration
      *a Timing Mark

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

      Tech Tips

      If the timing mark is not at the top, turn the crankshaft pulley 1 revolution so that the timing mark comes to the top (set the No. 1 piston to TDC/exhaust).

  32. REMOVE CRANKSHAFT PULLEY

    Click here

  33. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY

    Click here

  34. REMOVE TIMING GEAR COVER TIGHT PLUG

    Click here

  35. REMOVE TIMING CHAIN COVER OIL SEAL

    Click here

  36. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY


    1. A01VFRDE03
      Text in Illustration
      *1 Stopper Plate
      *2 Plunger
      A01VL3H Push Up
      A01VE7C Push

      Push up the stopper plate to release the lock and push in the plunger.

    2. A01VELWE02
      Text in Illustration
      *1 Stopper Plate
      A01VL3H Pull Down

      Pull down the stopper plate with the plunger pushed to the end and lock the plunger.

    3. A01VIDTE02
      Text in Illustration
      *1 Stopper Plate
      *a 3 mm Hexagon Wrench

      Insert a 3 mm hexagon wrench into the stopper plate hole.

    4. A01VE5F

      Remove the 2 bolts and No. 1 chain tensioner assembly with the chain tensioner gasket from the cylinder block sub-assembly.

    5. A01VFWH

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

  37. REMOVE TIMING CHAIN TENSION ARM


    1. A01VGPG

      Remove the bolt and timing chain tensioner arm from the cylinder block sub-assembly.

  38. REMOVE CHAIN SUB-ASSEMBLY


    1. Remove the chain sub-assembly.

  39. REMOVE TIMING CHAIN GUIDE


    1. A01VL56

      Remove the 2 bolts and timing chain guide from the cylinder head sub-assembly and cylinder block sub-assembly.

  40. REMOVE CRANKSHAFT TIMING GEAR OR SPROCKET


    1. A01VK6U

      Remove the crankshaft timing gear or sprocket from the crankshaft.

  41. REMOVE CRANKSHAFT STRAIGHT PIN


    1. A01VEIY

      Remove the crankshaft straight pin from the crankshaft.

  42. REMOVE CAMSHAFT TIMING SPROCKET ASSEMBLY


    1. A01VH5XE03

      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. A01VEK1E01
      Text in Illustration
      *a Turn
      *b Hold

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

  43. REMOVE CAMSHAFT TIMING GEAR


    1. A01VFJME01
      Text in Illustration
      *a Turn
      *b Hold

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

  44. REMOVE CAMSHAFT BEARING CAP


    1. A01VFX2E02
      Text in Illustration
      *1 No. 1 Camshaft Bearing Cap
      *2 No. 2 Camshaft Bearing Cap

      Remove the 15 bolts, No. 1 camshaft bearing cap and No. 2 camshaft bearing caps from the cylinder head sub-assembly in the order shown in the illustration.

  45. REMOVE NO. 2 CAMSHAFT


    1. A01VH39

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

  46. REMOVE CAMSHAFT


    1. A01VFP1

      Remove the camshaft from the cylinder head sub-assembly.

  47. REMOVE REAR ENGINE OIL SEAL RETAINER


    1. A01VDX8

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

  48. REMOVE STUD BOLT


    1. A01VGT8

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

  49. REMOVE ENGINE REAR OIL SEAL


    1. A01VL1SE02
      Text in Illustration
      *a Protective Tape
      *b Wooden Block

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

      Note

      Do not damage the surface of the rear engine oil seal retainer press fit hole.

  50. REMOVE VALVE LIFTER


    1. A01VFBB

      Remove the 12 valve lifters from the cylinder head sub-assembly.

      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

    Click here

  52. REMOVE CYLINDER HEAD GASKET

    Click here

  53. REMOVE CYLINDER BLOCK WATER JACKET SPACER


    1. A01VLEN

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