ENGINE UNIT DISASSEMBLY

PROCEDURE


  1. REMOVE OIL FILLER CAP SUB-ASSEMBLY


    1. A00560Y

      Remove the oil filler cap.

  2. REMOVE OIL FILLER CAP GASKET


    1. A0056SD

      Remove the oil filler cap gasket.

  3. REMOVE ENGINE COVER JOINT


    1. A0055YO

      Remove the 2 engine cover joints.

  4. REMOVE SPARK PLUG

    Click here

  5. REMOVE CAMSHAFT POSITION SENSOR


    1. A0055F5

      Remove the 2 bolts and 2 camshaft position sensors.

  6. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY


    1. A0052RW

      Remove the 2 bolts, wire harness bracket and 2 camshaft timing oil control valves.

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

  7. REMOVE CRANKSHAFT POSITION SENSOR


    1. A005605

      Remove the bolt and crankshaft position sensor.

  8. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY

    Click here

  9. REMOVE KNOCK SENSOR


    1. A00571E

      Remove the bolt and knock sensor.

  10. REMOVE ENGINE COOLANT TEMPERATURE SENSOR


    1. A00570QE06

      Using SST, remove the engine coolant temperature sensor and gasket.

      SST
      09817-33191
  11. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A0053W9

      Remove the 13 bolts, seal washer and cylinder head cover.

    2. A00595H

      Remove the 3 gaskets from the camshaft bearing cap.

      Note

      As gaskets may stick to the cylinder head cover, be careful not to drop any of the gaskets into the engine when removing the cylinder head cover.

  12. REMOVE CYLINDER HEAD COVER GASKET


    1. A00559T

      Remove the cylinder head cover gasket.

  13. REMOVE SPARK PLUG TUBE GASKET


    1. A0052DR

      Pry up the claws of the ventilation baffle plate.

      Note

      Do not deform the claws of the baffle plate more than necessary.

    2. A0054YB

      Using a screwdriver as shown in the illustration, deform each spark plug tube gasket inwards and remove the 4 spark plug tube gaskets from the cylinder head cover.

      Note


      • As much as possible prevent the spark plug tube gaskets from being deformed.

        The removed spark plug tube gaskets will be used when reinstalling the new spark plug tube gaskets.

      • Do not damage the cylinder head cover.

      • Make sure not to damage the spark plug tube gasket and cylinder head cover when inserting the screwdriver in the joint area.

      Tech Tips

      If the cylinder head cover is damaged, smooth the surface with 400-grit sandpaper.

  14. REMOVE OIL FILTER

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  15. REMOVE OIL FILTER UNION


    1. A0054T7

      Using a 12 mm socket hexagon wrench, remove the oil filter union.

  16. SET NO. 1 CYLINDER TO TDC/COMPRESSION

    Click here

  17. REMOVE CRANKSHAFT PULLEY

    Click here

  18. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY

    Click here

  19. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY

    Click here

  20. REMOVE TIMING CHAIN COVER OIL SEAL

    Click here

  21. REMOVE ENGINE MOUNTING BRACKET STUD BOLT

    Note

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

  22. REMOVE WATER INLET HOUSING STUD BOLT

    Note

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

  23. REMOVE WATER INLET HOUSING


    1. A0058JJ

      Remove the 3 bolts, water inlet housing and gasket.

  24. REMOVE NO. 1 GENERATOR BRACKET


    1. A0054TS

      Remove the 4 bolts and generator bracket.

  25. REMOVE CHAIN TENSIONER SLIPPER

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  26. REMOVE NO. 1 CHAIN VIBRATION DAMPER

    Click here

  27. REMOVE CHAIN SUB-ASSEMBLY

    Click here

  28. REMOVE NO. 2 CHAIN VIBRATION DAMPER

    Click here

  29. REMOVE CRANKSHAFT TIMING SPROCKET

    Click here

  30. REMOVE NO. 2 CHAIN SUB-ASSEMBLY

    Click here

  31. REMOVE NO. 1 CRANKSHAFT POSITION SENSOR PLATE


    1. A0053RN

      Remove the crankshaft position sensor plate.

  32. REMOVE CRANKSHAFT TIMING GEAR KEY


    1. A0053HPE02
      Text in Illustration
      *1 Protective Tape

      Using a screwdriver, remove the 2 crankshaft timing gear keys.

      Tech Tips

      Tape the screwdriver tip before use.

  33. INSPECT CAMSHAFT TIMING GEAR ASSEMBLY

    Click here

  34. INSPECT CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY

    Click here

  35. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY

    Click here

  36. REMOVE CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY

    Click here

  37. REMOVE CAMSHAFT BEARING CAP

    Click here

  38. REMOVE CAMSHAFT

    Click here

  39. REMOVE NO. 2 CAMSHAFT

    Click here

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


    1. A0054RU

      Remove the 16 valve rocker arms.

      Tech Tips

      Arrange the removed parts in the correct order.

  41. REMOVE VALVE LASH ADJUSTER ASSEMBLY


    1. A0055A7

      Remove the 16 valve lash adjusters from the cylinder head.

      Tech Tips

      Arrange the removed parts in the correct order.

  42. REMOVE OIL CONTROL VALVE FILTER


    1. A00577H

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

  43. REMOVE NO. 1 CAMSHAFT BEARING


    1. A0052JM

      Remove the 2 camshaft bearings.

  44. REMOVE NO. 2 CAMSHAFT BEARING


    1. A0054AT

      Remove the 2 camshaft bearings.

  45. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY

    Click here

  46. REMOVE VALVE STEM CAP


    1. A0053FN

      Remove the 16 valve stem caps.

      Tech Tips

      Arrange the removed parts in the correct order.

  47. REMOVE CAMSHAFT HOUSING STRAIGHT PIN

    Note

    It is not necessary to remove a straight pin unless it is being replaced.

  48. REMOVE CYLINDER HEAD SUB-ASSEMBLY

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  49. REMOVE CYLINDER HEAD GASKET

    Click here

  50. REMOVE VENTILATION VALVE SUB-ASSEMBLY

    Click here

  51. REMOVE OIL PAN DRAIN PLUG


    1. A0057YP

      Remove the drain plug and gasket.

  52. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY

    Click here

  53. REMOVE OIL PUMP ASSEMBLY

    Click here

  54. REMOVE STIFFENING CRANKCASE ASSEMBLY


    1. A005902

      Uniformly loosen and remove the 11 bolts.

    2. A0053G8E17
      Text in Illustration
      *1 Protective Tape

      Using a screwdriver, remove the stiffening crankcase by prying between the stiffening crankcase and cylinder block.

      Tech Tips

      Tape the screwdriver tip before use.

      Note

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

  55. REMOVE NO. 1 TAPER SCREW PLUG


    1. A00559L

      Remove the 2 No. 1 taper screw plugs.

  56. REMOVE STIFFENING CRANKCASE STUD BOLT

    Note

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

  57. REMOVE STIFFENING CRANKCASE RING PIN

    Note

    It is not necessary to remove a ring pin unless it is being replaced.

  58. REMOVE ENGINE REAR OIL SEAL


    1. A00567P

      Remove the engine rear oil seal from the cylinder block.