ENGINE UNIT DISASSEMBLY

PROCEDURE


  1. REMOVE REAR ENGINE OIL SEAL (w/o Stop and Start System)


    1. A01VDLPE12
      Text in Illustration
      *1 Protective Tape
      *a Cut Position

      Using a knife, cut off the oil seal lip.

    2. Using a screwdriver with its tip wrapped with protective tape, pry out the rear engine oil seal.

  2. REMOVE REAR ENGINE OIL SEAL (w/ Stop and Start System)


    1. A01VL4UE02
      Text in Illustration
      *1 Protective Tape

      Using a screwdriver with its tip wrapped with protective tape, pry out the rear engine oil seal.

      Note


      • If the snap ring is broken, the ring gear may move out from its original position and result in an oil leak. Therefore, it is necessary to confirm that the snap ring is installed correctly and undamaged when replacing the oil seal.

      • Be careful not to damage the crankshaft bearing.

  3. REMOVE CRANKSHAFT BEARING (w/ Stop and Start System)


    1. A01VLRKE05

      Using SST, hold the crankshaft.

      SST
      09960-10010   ( 09962-01000, 09963-01000 )
    2. A01VH7CE05
      Text in Illustration
      *a Turn
      *b Hold

      Using SST, remove the crankshaft bearing from the crankshaft.

      SST
      09950-40011   ( 09951-04010, 09952-04010, 09953-04020, 09954-04010, 09955-04071, 09957-04010, 09958-04011 )
      09950-60010   ( 09951-00280, 09951-00380, 09952-06010 )

    3. Remove the snap ring from the bearing.

  4. REMOVE OIL FILLER CAP SUB-ASSEMBLY


    1. A01VG48

      Remove the oil filler cap.

  5. REMOVE OIL FILLER CAP GASKET


    1. A01VFHD

      Remove the gasket from the oil filler cap.

  6. REMOVE SPARK PLUG


    1. A01VG3D

      Using a 14 mm spark plug wrench, remove the 4 spark plugs.

  7. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY


    1. A01VM5Y

      Remove the 2 bolts and 2 camshaft timing oil control valve assemblies.

    2. Remove the 2 O-rings from the camshaft timing oil control valve assembly.

  8. REMOVE CAMSHAFT POSITION SENSOR


    1. A01VKKD

      Remove the 2 bolts and 2 camshaft position sensors.

  9. REMOVE VENTILATION VALVE SUB-ASSEMBLY


    1. A01VK06

      Remove the ventilation valve sub-assembly.

  10. REMOVE VENTILATION SYSTEM GROMMET


    1. A01VK9Y

      Remove the ventilation system grommet from the cylinder head cover.

  11. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A01VLKCE01
      Text in Illustration
      *1 Seal Washer

      Remove the 17 bolts, 2 seal washers and cylinder head cover.

      Note

      Be careful not to drop any of the gaskets into the engine when removing the cylinder head cover because the gaskets may stick to the cylinder head cover.

    2. A01VFKW

      Remove the cylinder head cover gasket.

    3. A01VEPO

      Remove the 2 camshaft bearing cap oil hole gaskets from the camshaft bearing cap.

  12. REMOVE CRANKSHAFT POSITION SENSOR


    1. A01VKCX

      Remove the bolt and crankshaft position sensor.

  13. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY


    1. A01VJZC

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

  14. REMOVE KNOCK SENSOR


    1. A01VEFV

      Remove the bolt and knock sensor.

  15. REMOVE ENGINE COOLANT TEMPERATURE SENSOR


    1. A01VLM2

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

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

  16. REMOVE OIL FILTER ELEMENT

    Click here

  17. REMOVE WATER INLET

    Click here

  18. REMOVE THERMOSTAT

    Click here

  19. SET NO. 1 CYLINDER TO TDC/COMPRESSION


    1. Turn the crankshaft pulley until its groove and the groove of the timing chain cover are aligned.

      A01VI6WE01
      Text in Illustration
      *a Timing Mark
      *b Groove

    2. Check that each timing mark of the camshaft timing gear and sprocket are located as shown in the illustration. If not, turn the crankshaft 1 revolution (360°) to align the timing marks as shown in the illustration.

  20. REMOVE CRANKSHAFT PULLEY


    1. A01VLAUE03
      Text in Illustration
      *a Loosen
      *b Hold

      Using SST, remove the crankshaft pulley bolt.

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

    2. Remove the crankshaft pulley from the crankshaft.

  21. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY


    1. A01VK4L

      Remove the 9 bolts and engine water pump assembly from the timing chain cover.

    2. A01VJLS

      Remove the 3 bolts and engine mounting bracket RH.

    3. A01VIZE

      Remove the 21 bolts.

    4. A01VHZNE02
      Text in Illustration
      *1 Protective Tape

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

      Note

      Be careful not to damage the contact surfaces of the timing chain cover, cylinder block, and cylinder head.

    5. A01VHCH

      Remove the 2 O-rings.

    6. A01VF7H

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

  22. REMOVE TIMING CHAIN COVER OIL SEAL


    1. A01VEPAE01
      Text in Illustration
      *1 Protective Tape
      *2 Wooden Block

      Using a screwdriver with its tip wrapped with protective tape, remove the timing chain cover oil seal.

  23. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY


    1. Set the camshaft timing gear, camshaft timing exhaust gear and crankshaft in the positions (20° ATDC) shown in the illustration.

      A01VF31E01
      Text in Illustration
      *a Timing Mark
    2. A01VGCRE05
      Text in Illustration
      *1 Stopper Plate
      *2 Plunger
      *a Push

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

    3. A01VGXGE02
      Text in Illustration
      *1 Stopper Plate

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

    4. A01VJ95E02
      Text in Illustration
      *1 Bar

      Insert a 3 mm (0.118 in.) diameter bar into the hole in the stopper plate and lock the plunger.

    5. A01VHCC

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

    6. A01VJSP

      Remove the gasket from the cylinder head.

  24. REMOVE NO. 2 CHAIN VIBRATION DAMPER


    1. A01VFZ0

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

  25. REMOVE TIMING CHAIN TENSION ARM


    1. A01VHP2

      Remove the bolt and timing chain tension arm.

  26. REMOVE CHAIN SUB-ASSEMBLY


    1. Remove the chain sub-assembly.

  27. REMOVE TIMING CHAIN GUIDE


    1. A01VFTB

      Remove the 2 bolts and timing chain guide.

  28. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY


    1. A01VH9HE08

      Check the lock of the camshaft timing gear.

    2. Release the lock pin.

      Note

      Before removing the camshaft timing gear assembly, make sure that the lock pin has been released.


      1. After cleaning and degreasing the VVT oil hole on the intake side of the No. 1 camshaft bearing cap, completely seal the oil hole with adhesive tape or equivalent as shown in the illustration to prevent air from leaking.

        Note

        Be sure to cover the oil hole completely because air leaks due to insufficient sealing will prevent the lock pin from being released.

      2. Prick a hole in the tape covering the oil hole as shown in the illustration (Procedure A).

      3. A01VLX5
        Text in Illustration
        *1 Adhesive Tape
        *a Adhesive Tape Sealing Area
        *b Prick a Hole

        Apply approximately 150 kPa (1.5 kgf/cm2, 22 psi) of air pressure to the hole pricked in procedure A to release the lock pin.

        Note


        • If air leaks out, reattach adhesive tape.

        • Cover the oil hole with a piece of cloth when applying air pressure to prevent oil from spraying.

        • Do not lock the camshaft timing gear assembly. If it is locked, release the lock pin again.

        Tech Tips


        • The camshaft timing gear assembly may be turned in the advance direction without applying any force.

        • If enough air pressure cannot be applied because of air leakage from the port, releasing the lock pin may be difficult.

      4. Remove the adhesive tape from the No. 1 camshaft bearing cap.

    3. A01VDPJE05
      Text in Illustration
      *a Do Not Remove

      Remove the flange bolt while holding the hexagonal portion of the camshaft, and then remove the camshaft timing gear assembly.

      Note


      • Before removing the camshaft timing gear, make sure that the lock pin has been released.

      • Be sure not to remove the other 4 bolts.

      • Keep the camshaft timing gear assembly horizontal while removing it from the camshaft.

  29. REMOVE CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY


    1. A01VM8YE04
      Text in Illustration
      *a Do Not Remove

      Remove the flange bolt while holding the hexagonal portion of the camshaft, and then remove the camshaft timing exhaust gear assembly.

      Note


      • Be sure not to remove the other 4 bolts.

      • Keep the camshaft timing exhaust gear assembly horizontal while removing it from the camshaft.

  30. REMOVE CAMSHAFT BEARING CAP


    1. A01VHQJE02

      Uniformly loosen and remove the 5 bearing cap bolts in the sequence shown in the illustration.

    2. A01VLMOE02

      Uniformly loosen and remove the 15 bearing cap bolts in the sequence shown in the illustration.

      Note

      Uniformly loosen the bolts while keeping the camshaft level.

    3. Remove the 5 bearing caps.

      Tech Tips

      Arrange the removed parts in the correct order.

  31. REMOVE NO. 2 CAMSHAFT


    1. A01VEEJ

      Remove the No. 2 camshaft.

  32. REMOVE CAMSHAFT


    1. A01VHQ4

      Remove the camshaft.

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

    A01VKDDE01

    Tech Tips

    Type A and Type B can be distinguished by the shape of the outer compression spring.

    Type Outer Compression Spring Shape
    A Straight
    B Taper
    *A Type A
    *B Type B
    *1 No. 1 Valve Rocker Arm Sub-assembly
    *2 Valve Spring Retainer
    *3 Outer Compression Spring
    *4 Valve Lash Adjuster Assembly

    1. Type A and Type B:


      1. A01VH17

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

        Tech Tips

        Arrange the removed parts in the correct order.

  34. REMOVE VALVE LASH ADJUSTER ASSEMBLY

    A01VKDDE01

    Tech Tips

    Type A and Type B can be distinguished by the shape of the outer compression spring.

    Type Outer Compression Spring Shape
    A Straight
    B Taper
    *A Type A
    *B Type B
    *1 No. 1 Valve Rocker Arm Sub-assembly
    *2 Valve Spring Retainer
    *3 Outer Compression Spring
    *4 Valve Lash Adjuster Assembly

    1. Type A and Type B:


      1. A01VJOQ

        Remove the 16 valve lash adjuster assemblies from the cylinder head.

        Tech Tips

        Arrange the removed parts in the correct order.

  35. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY


    1. A01VEOC

      Remove the 3 bolts.

    2. A01VH36E02
      Text in Illustration
      *1 Protective Tape

      Using a screwdriver with its tip wrapped with protective tape, remove the camshaft housing by prying between the cylinder head and camshaft housing.

      Note

      Be careful not to damage the contact surfaces of the cylinder head and camshaft housing.

  36. REMOVE CYLINDER HEAD SUB-ASSEMBLY


    1. A01VJR4E02

      Using several steps, uniformly loosen and remove the 10 cylinder head bolts and 10 plate washers with a 10 mm bi-hexagon wrench in the sequence shown in the illustration.

      Note

      Head warpage or cracking could result from removing the bolts in the wrong order.

    2. Using a screwdriver with its tip wrapped with protective tape, pry between the cylinder head and cylinder block, and remove the cylinder head.

      Note

      Be careful not to damage the contact surfaces of the cylinder head and cylinder block.

  37. REMOVE CYLINDER HEAD GASKET


    1. A01VG5O

      Remove the cylinder head gasket.

  38. REMOVE CYLINDER BLOCK WATER JACKET SPACER


    1. A01VHEJ

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

  39. REMOVE OIL PAN DRAIN PLUG


    1. A01VIH1

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

  40. REMOVE OIL PAN SUB-ASSEMBLY


    1. A01VJ67

      Uniformly loosen and remove the 10 bolts.

    2. A01VH0GE02
      Text in Illustration
      *1 Protective Tape

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

      Note

      Be careful not to damage the contact surfaces of the crankcase and cylinder block.

    3. A01VGJV

      Remove the gasket from the cylinder block.

  41. REMOVE NO. 1 OIL PAN BAFFLE PLATE


    1. A01VIYW

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

  42. REMOVE OIL STRAINER SUB-ASSEMBLY


    1. A01VEAX

      Remove the 2 bolts and oil strainer sub-assembly from the oil pan.