ENGINE UNIT DISASSEMBLY

PROCEDURE


  1. REMOVE OIL FILLER CAP SUB-ASSEMBLY


    1. B001KWM

      Remove the oil filler cap.

  2. REMOVE OIL FILLER CAP GASKET


    1. B001LPI

      Remove the oil filler cap gasket.

  3. REMOVE ENGINE COVER JOINT BOLT


    1. B001LXZ

      Remove the 3 engine cover joint bolts.

  4. REMOVE WIRING HARNESS CLAMP BRACKET


    1. B001M1M

      Remove the bolt and wiring harness clamp bracket.

  5. REMOVE SPARK PLUG

    Click here

  6. REMOVE CAMSHAFT POSITION SENSOR


    1. B001K9W

      Remove the bolt and camshaft position sensor.

  7. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY


    1. B001LT5

      Remove the bolt and camshaft timing oil control valve.

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

  8. REMOVE CRANKSHAFT POSITION SENSOR


    1. A004WNH

      Remove the bolt and crankshaft position sensor.

  9. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY


    1. A004WBX

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

  10. REMOVE KNOCK SENSOR


    1. B001M42

      Remove the bolt and knock sensor.

  11. REMOVE ENGINE COOLANT TEMPERATURE SENSOR


    1. B001NAS

      Remove the engine coolant temperature sensor and gasket.

  12. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY


    1. B001NCL

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

      Note

      As the 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.

    2. B001LMN

      Remove the 2 gaskets from the camshaft bearing cap.

  13. REMOVE CYLINDER HEAD COVER GASKET


    1. B001MT6

      Remove the cylinder head cover gasket.

  14. REMOVE SPARK PLUG TUBE GASKET


    1. B001M5F

      Pry up the claws of the ventilation baffle plate.

      Note

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

    2. B001LIG

      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 sub-assembly.

      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 sub-assembly.

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

      Tech Tips

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

  15. REMOVE OIL FILTER CAP ASSEMBLY

    Click here

  16. REMOVE INLET WATER SUB-ASSEMBLY


    1. Type A:


      1. B001L4Z

        Remove the bolt, 2 nuts, inlet water sub-assembly and gasket.

    2. Type B:


      1. B001M85

        Remove the 3 bolts, inlet water sub-assembly and gasket.

  17. REMOVE INLET WATER SUB-ASSEMBLY STUD BOLT

    Note

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

  18. SET NO. 1 CYLINDER TO TDC/COMPRESSION

    Click here

  19. REMOVE CRANKSHAFT PULLEY

    Click here

  20. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY

    Click here

  21. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY

    Click here

  22. REMOVE TIMING CHAIN COVER OIL SEAL

    Click here

  23. REMOVE CHAIN TENSIONER SLIPPER

    Click here

  24. REMOVE NO. 1 CHAIN VIBRATION DAMPER

    Click here

  25. REMOVE NO. 2 CHAIN VIBRATION DAMPER

    Click here

  26. REMOVE CHAIN SUB-ASSEMBLY

    Click here

  27. REMOVE CRANKSHAFT TIMING SPROCKET

    Click here

  28. REMOVE NO. 2 CHAIN SUB-ASSEMBLY

    Click here

  29. REMOVE NO. 1 CRANKSHAFT POSITION SENSOR PLATE


    1. B001MGO

      Remove the crankshaft position sensor plate.

  30. REMOVE CRANKSHAFT TIMING GEAR KEY


    1. B001N0ME08
      Text in Illustration
      *1 Protective Tape

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

      Tech Tips

      Tape the screwdriver tip before use.

  31. INSPECT CAMSHAFT TIMING GEAR ASSEMBLY

    Click here

  32. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY

    Click here

  33. REMOVE CAMSHAFT TIMING SPROCKET

    Click here

  34. REMOVE CAMSHAFT BEARING CAP

    Click here

  35. REMOVE CAMSHAFT

    Click here

  36. REMOVE NO. 2 CAMSHAFT

    Click here

  37. REMOVE CAMSHAFT HOUSING STRAIGHT PIN

    Note

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

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


    1. B001MKE

      Remove the 16 valve rocker arms.

      Tech Tips

      Arrange the removed parts in the correct order.

  39. REMOVE VALVE LASH ADJUSTER ASSEMBLY


    1. B001LMH

      Remove the 16 valve lash adjusters from the cylinder head.

      Tech Tips

      Arrange the removed parts in the correct order.

  40. REMOVE VALVE STEM CAP


    1. B001LHN

      Remove the 16 valve stem caps.

      Tech Tips

      Arrange the removed parts in the correct order.

  41. REMOVE OIL CONTROL VALVE FILTER


    1. B001NFV

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

  42. REMOVE NO. 1 CAMSHAFT BEARING


    1. B001N03

      Remove the 2 camshaft bearings.

  43. REMOVE NO. 2 CAMSHAFT BEARING


    1. B001L6X

      Remove the 2 camshaft bearings.

  44. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY

    Click here

  45. REMOVE CYLINDER HEAD SUB-ASSEMBLY

    Click here

  46. REMOVE CYLINDER HEAD GASKET

    Click here

  47. REMOVE VENTILATION VALVE SUB-ASSEMBLY


    1. B001L6M

      Remove the ventilation valve sub-assembly.

  48. REMOVE OIL PAN DRAIN PLUG


    1. B001LWL

      Remove the drain plug and gasket.

  49. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY

    Click here

  50. REMOVE OIL PUMP ASSEMBLY

    Click here

  51. REMOVE STIFFENING CRANKCASE ASSEMBLY


    1. B001M8D

      Uniformly loosen and remove the 11 bolts.

    2. B001MGCE06
      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.

  52. REMOVE NO. 1 TAPER SCREW PLUG


    1. A004ZPH

      Remove the 2 No. 1 taper screw plugs.

  53. REMOVE STIFFENING CRANKCASE STUD BOLT

    Note

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

  54. REMOVE STIFFENING CRANKCASE RING PIN

    Note

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

  55. REMOVE ENGINE REAR OIL SEAL


    1. B001MN0

      Remove the engine rear oil seal from the cylinder block.