ENGINE UNIT DISASSEMBLY

PROCEDURE


  1. REMOVE WATER TEMPERATURE SENSOR

    A01VDKTE06

    1. Using SST, remove the water temperature sensor and gasket.

      SST
      09817-33190

  2. REMOVE WATER OUTLET SUB-ASSEMBLY

    A01VFZZ

    1. Remove the 2 bolts, 2 nuts and water outlet sub-assembly.

    2. Remove the water outlet gasket from the cylinder head.

  3. REMOVE WATER INLET


    1. A01VJ8B

      Remove the 3 bolts and the water inlet.

    2. Remove the No. 1 water inlet housing gasket from the water inlet.

  4. REMOVE OIL PRESSURE SENDER GAUGE ASSEMBLY (w/ DPF)

    A01VGR8E02
    Text in Illustration
    *1 27 mm Deep Socket Wrench

    1. Using a 27 mm deep socket wrench, remove the oil pressure sender gauge assembly.

  5. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY (w/o DPF)

    A01VGR8E02
    Text in Illustration
    *1 27 mm Deep Socket Wrench

    1. Using a 27 mm deep socket wrench, remove the oil pressure switch assembly.

  6. REMOVE OIL FILLER CAP SUB-ASSEMBLY


    1. Remove the oil filler cap from the cylinder head cover.

    2. Using a screwdriver with its tip wrapped in protective tape, remove the oil filler cap gasket.

  7. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A01VJ2B

      Remove the 12 bolts and the cylinder head cover.

    2. Remove the cylinder head cover gasket from the cylinder head cover.

  8. REMOVE ENGINE MOUNTING BRACKET RH


    1. A01VJ28

      Remove the 4 bolts and the engine mounting bracket RH.

  9. REMOVE NO. 2 TIMING CHAIN COVER (w/ DPF)

    A01VIY4

    1. Remove the bolt, manifold temperature sensor bracket and the No. 2 timing chain cover.

  10. REMOVE NO. 2 TIMING CHAIN COVER (w/o DPF)

    A01VE40

    1. Remove the bolt, washer plate and the No. 2 timing chain cover.

  11. REMOVE CRANKSHAFT DAMPER SUB-ASSEMBLY

    Click here

  12. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY (w/ DPF)


    1. A01VHRN

      Remove the 20 bolts and the 2 nuts.

    2. A01VI06E01
      Text in Illustration
      *1 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 and cylinder block.

      Note

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

    3. A01VGCF

      Remove the oil pump gasket.

  13. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY (w/o DPF)


    1. A01VL0A

      Remove the 20 bolts and the 2 nuts.

    2. A01VI06E01
      Text in Illustration
      *1 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 and cylinder block.

      Note

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

  14. REMOVE TIMING CHAIN COVER OIL SEAL

    A01VFHPE01
    Text in Illustration
    *1 Protective Tape

    1. Using a screwdriver with its tip wrapped in protective tape, remove the oil seal.

  15. REMOVE OIL CHECK VALVE SUB-ASSEMBLY (w/ DPF)


    1. A01VFXG

      Using a 6 mm hexagon wrench, remove the bolt and oil check valve sub-assembly from the timing chain cover sub-assembly.

  16. INSPECT OIL CHECK VALVE SUB-ASSEMBLY (w/ DPF)


    1. A01VEQIE01
      Text in Illustration
      *1 Ball

      Push the ball of the oil check valve sub-assembly to check if it is stuck.

      Note

      If the check valve is stuck, replace the oil check valve sub-assembly.

  17. REMOVE WATER INLET HOUSING

    A01VICB

    1. Remove the 3 bolts and the water inlet housing from the timing chain cover.

    2. Remove the No. 2 water inlet housing gasket from the water inlet housing.

  18. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY

    Note

    Do not rotate the crankshaft with the chain tensioner removed.


    1. A01VG6BE07
      Text in Illustration
      *1 Plunger
      *2 Groove
      *3 Hole
      *a Push

      Push in the plunger until the groove is aligned with the tensioner hole, and then insert a 1.1 mm (0.043 in.) diameter bar.

    2. A01VDIE

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

  19. REMOVE CHAIN TENSIONER SLIPPER


    1. A01VL57

      Remove the chain tensioner slipper.

  20. REMOVE NO. 1 CHAIN VIBRATION DAMPER


    1. A01VEGV

      Using an 8 mm socket hexagon wrench, remove the 2 bolts and the No. 1 chain vibration damper.

  21. REMOVE CHAIN SUB-ASSEMBLY


    1. A01VJSBE01

      Using SST, hold the camshaft timing sprocket.

      SST
      09960-10010   ( 09962-01000, 09963-01000 )

    2. Remove the 3 bolts and the camshaft timing sprocket.

    3. A01VJYW

      Remove the camshaft timing sprocket, crankshaft timing sprocket and chain together.

  22. REMOVE NO. 2 CHAIN SUB-ASSEMBLY

    A01VDYT

    1. Remove the chain tensioner plate with the chain damper spring from the pin.

    2. A01VJY4

      Insert a 4 mm (0.157 in.) diameter bar into the adjusting hole of the oil pump drive shaft gear to lock the gear in position, and then remove the nut.

    3. A01VJ8G

      Remove the oil pump drive gear, oil pump drive shaft gear and No. 2 chain.

  23. REMOVE CHAIN DAMPER SPRING

    A01VDL9

    1. Remove the chain damper spring from the chain tensioner plate.

  24. REMOVE CAMSHAFT

    Click here

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


    1. A01VJUH

      Remove the No. 1 valve rocker arm from the cylinder head.

  26. REMOVE CYLINDER HEAD SUB-ASSEMBLY


    1. A01VI94E01

      Using several steps, loosen the 10 bolts in the order shown in the illustration, and then remove the bolts and washers.

      Note


      • When removing the bolts, do not drop the washers into the engine.

      • Removing the cylinder head bolts in the wrong order may cause damage to the cylinder head.

    2. Remove the cylinder head.

  27. REMOVE CYLINDER HEAD GASKET

    Click here

  28. REMOVE CYLINDER BLOCK WATER JACKET SPACER

    A01VF71

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

  29. REMOVE OIL FILTER CAP ASSEMBLY WITH ELEMENT

    A01VFY9E01

    1. Using SST, remove the oil filter cap.

      SST
      09228-06501

  30. REMOVE OIL FILTER ELEMENT

    Click here

  31. REMOVE OIL COOLER ASSEMBLY

    A01VM1S

    1. Remove the 2 bolts, 2 nuts and oil cooler.

    2. A01VE61

      Remove the 2 O-rings and oil cooler gasket from the oil filter bracket.

  32. REMOVE OIL FILTER BRACKET SUB-ASSEMBLY

    A01VL03

    1. Remove the 2 bolts and oil filter bracket from the oil pan.

    2. A01VLW3

      Remove the oil filter bracket gasket from the oil pan.

  33. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY


    1. A01VLJ9

      Remove the oil pan drain plug and the oil pan drain plug gasket.

    2. Remove the 10 bolts and 2 nuts.

    3. A01VLLBE04
      Text in Illustration
      *1 Oil Pan Seal Cutter

      Insert the oil pan seal cutter blade between the oil pan and No. 2 oil pan, and cut off the applied sealer.

      Note

      Do not damage the oil pan or No. 2 oil pan.

    4. Remove No. 2 oil pan.

  34. REMOVE ENGINE OIL LEVEL SENSOR (w/ DPF)

    A01VDWS

    1. Remove the 5 bolts and the engine oil level sensor.

  35. REMOVE ENGINE OIL LEVEL SENSOR (w/o DPF)

    A01VGBM

    1. Remove the 4 bolts and the engine oil level sensor.

  36. REMOVE OIL PAN SUB-ASSEMBLY


    1. A01VEEP

      Remove the 12 bolts.

    2. A01VFB8E04
      Text in Illustration
      *1 Protective Tape

      Using a screwdriver with its tip wrapped in protective tape, remove the oil pan by prying between the cylinder block and oil pan as illustrated.

      Note

      Do not apply excessive force when prying between the cylinder block and oil pan.

  37. REMOVE ENGINE REAR OIL SEAL


    1. A01VIMS

      Remove the engine rear oil seal.