ENGINE UNIT DISASSEMBLY

PROCEDURE


  1. REMOVE OIL FILLER CAP SUB-ASSEMBLY


    1. B001KWM

      Remove the oil filler cap sub-assembly.

  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 assembly.

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

  8. REMOVE CRANKSHAFT POSITION SENSOR


    1. B001NCM

      Remove the bolt and crankshaft position sensor.

  9. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY


    1. B001MSW

      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 sub-assembly.

      Note

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

    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.

      • Prevent the spark plug tube gaskets from being deformed as much as possible. The removed spark plug tube gaskets will be used when installing new spark plug tube gaskets.

  15. REMOVE OIL FILTER

    Click here

  16. REMOVE OIL FILTER UNION (for Oil Filter Sub-assembly Type)

    B001KX0

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

  17. REMOVE WATER INLET SUB-ASSEMBLY


    1. Type A:


      1. B001L4Z

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

    2. Type B:


      1. B001M85

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

  18. REMOVE INLET WATER SUB-ASSEMBLY STUD BOLT

    Note

    If an inlet water sub-assembly stud bolt is deformed or its threads are damaged, replace it.

  19. SET NO. 1 CYLINDER TO TDC/COMPRESSION

    Click here

  20. REMOVE CRANKSHAFT PULLEY

    Click here

  21. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY

    Click here

  22. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY

    Click here

  23. REMOVE TIMING CHAIN COVER OIL SEAL

    Click here

  24. REMOVE CHAIN TENSIONER SLIPPER

    Click here

  25. REMOVE NO. 1 CHAIN VIBRATION DAMPER

    Click here

  26. REMOVE NO. 2 CHAIN VIBRATION DAMPER

    Click here

  27. REMOVE CHAIN SUB-ASSEMBLY

    Click here

  28. REMOVE CRANKSHAFT TIMING SPROCKET

    Click here

  29. REMOVE NO. 2 CHAIN SUB-ASSEMBLY

    Click here

  30. REMOVE NO. 1 CRANKSHAFT POSITION SENSOR PLATE


    1. B001MGO

      Remove the No. 1 crankshaft position sensor plate.

  31. 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.

  32. INSPECT CAMSHAFT TIMING GEAR ASSEMBLY

    Click here

  33. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY

    Click here

  34. REMOVE CAMSHAFT TIMING SPROCKET

    Click here

  35. REMOVE CAMSHAFT BEARING CAP

    Click here

  36. REMOVE CAMSHAFT

    Click here

  37. REMOVE NO. 2 CAMSHAFT

    Click here

  38. REMOVE CAMSHAFT HOUSING STRAIGHT PIN

    Note

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

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


    1. B001MKE

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

      Tech Tips

      Arrange the removed parts in the correct order.

  40. REMOVE VALVE LASH ADJUSTER ASSEMBLY


    1. B001LMH

      Remove the 16 valve lash adjuster assemblies from the cylinder head sub-assembly.

      Tech Tips

      Arrange the removed parts in the correct order.

  41. REMOVE VALVE STEM CAP


    1. B001LHN

      Remove the 16 valve stem caps.

      Tech Tips

      Arrange the removed parts in the correct order.

  42. REMOVE OIL CONTROL VALVE FILTER


    1. B001NFV

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

  43. REMOVE NO. 1 CAMSHAFT BEARING


    1. B001N03

      Remove the 2 No. 1 camshaft bearings.

  44. REMOVE NO. 2 CAMSHAFT BEARING


    1. B001L6X

      Remove the 2 No. 2 camshaft bearings.

  45. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY

    Click here

  46. REMOVE CYLINDER HEAD SUB-ASSEMBLY

    Click here

  47. REMOVE CYLINDER HEAD GASKET

    Click here

  48. REMOVE VENTILATION VALVE SUB-ASSEMBLY


    1. B001L6M

      Remove the ventilation valve sub-assembly.

  49. REMOVE OIL PAN DRAIN PLUG


    1. B001LWL

      Remove the oil pan drain plug and gasket.

  50. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY

    Click here

  51. REMOVE OIL PUMP ASSEMBLY

    Click here

  52. 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 assembly by prying between the stiffening crankcase assembly and cylinder block.

      Note

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

      Tech Tips

      Tape the screwdriver tip before use.

  53. REMOVE NO. 1 TAPER SCREW PLUG


    1. B001M5W

      Remove the No. 1 taper screw plug.

  54. REMOVE STIFFENING CRANKCASE STUD BOLT

    Note

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

  55. REMOVE STIFFENING CRANKCASE RING PIN

    Note

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

  56. REMOVE REAR ENGINE OIL SEAL


    1. B001MN0

      Remove the rear engine oil seal from the cylinder block.