ENGINE UNIT DISASSEMBLY

PROCEDURE

1. Click here

   REMOVE OIL FILTER ELEMENT

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2. Click here

   REMOVE OIL PRESSURE SENDER GAUGE ASSEMBLY

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3. Click here

   REMOVE OIL FILTER BRACKET SUB-ASSEMBLY

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4. Click here

   REMOVE CRANKSHAFT PULLEY

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5. Click here

   REMOVE OIL FILLER CAP SUB-ASSEMBLY

   
   

   1. Remove the oil filler cap.

   2. Remove the gasket from the oil filler cap.

6. Click here

   REMOVE OIL FILLER CAP HOUSING

   
   
   1. 

      Remove the 2 bolts, oil filler cap housing and gasket.

7. Click here

   REMOVE SPARK PLUG

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8. Click here

   REMOVE KNOCK SENSOR

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9. Click here

   REMOVE VVT SENSOR

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10. Click here

    REMOVE CAMSHAFT POSITION SENSOR

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11. Click here

    REMOVE CRANKSHAFT POSITION SENSOR PROTECTOR

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12. Click here

    REMOVE CRANKSHAFT POSITION SENSOR

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13. Click here

    REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY

    
    
    1. 

       for Bank 1:

       Remove the 2 bolts and 2 camshaft oil control valves.

    2. 

       for Bank 2:

       Remove the 2 bolts and 2 camshaft oil control valves.

14. Click here

    REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY

    
    
    1. 

       Remove the 2 water drain cock plugs from the cylinder block water drain cocks.

       Table 1. Text in Illustration

       *A	for LH Side
       *B	for RH Side

    2. Remove the 2 cylinder block water drain cocks from the cylinder block.

15. Click here

    REMOVE WATER INLET HOUSING

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16. Click here

    REMOVE FRONT WATER BY-PASS JOINT

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17. Click here

    REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH

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18. Click here

    REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY RH

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19. Click here

    REMOVE OIL CONTROL VALVE FILTER

    
    
    1. 

       for Bank 1:

       Remove the 3 bolts, cylinder head cover spacer, gasket and oil control valve filter.

       Table 2. Text in Illustration

       *1	Cylinder Head Cover Spacer
       *2	Gasket
       *3	Oil Control Valve Filter

    2. 

       for Bank 2:

       Remove the 3 bolts, cylinder head cover spacer, gasket and oil control valve filter.

       Table 3. Text in Illustration

       *1	Cylinder Head Cover Spacer
       *2	Gasket
       *3	Oil Control Valve Filter

20. Click here

    REMOVE SPARK PLUG TUBE GASKET

    
    
    1. 

       Bend the 4 ventilation baffle plate claws on the cylinder head cover to an angle of 90° or more.

       Table 4. Text in Illustration

       *1	Ventilation Baffle Plate Claw
       *2	Protective Tape

    2. Using a screwdriver, pry out the gaskets.

       Note:

       Be careful not to damage the cylinder head cover.

       Tip:
       

       • Be careful not to damage the gasket when removing it as the removed gasket needs to be used when installing a new one.

       • Tape the screwdriver tip before use.

21. Click here

    REMOVE ENGINE OIL LEVEL SENSOR

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22. Click here

    REMOVE V-RIBBED BELT TENSIONER ASSEMBLY

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23. Click here

    REMOVE TIMING CHAIN COVER SUB-ASSEMBLY

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24. Click here

    REMOVE ENGINE WATER PUMP ASSEMBLY

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25. Click here

    REMOVE WATER INLET PIPE

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26. Click here

    REMOVE FRONT CRANKSHAFT OIL SEAL

    
    

    1. Place the timing chain cover on wooden blocks.

    2. 

       Place the oil pump on a wooden block.

       Table 5. Text in Illustration

       *1	Wooden Block
       *2	Protective Tape

    3. Using a screwdriver and wooden block, pry out the front crankshaft oil seal.

       Note:

       Do not damage the surface of the front crankshaft oil seal press fit hole.

       Tip:

       Tape the screwdriver tip before use.

27. Click here

    SET NO. 1 CYLINDER TO TDC/COMPRESSION

    
    

    1. Temporarily install the pulley set bolt.

    2. 

       Rotate the crankshaft clockwise so that the timing marks on the crankshaft timing gear and camshaft timing gears are as shown in the illustration.

       Tip:

       If the timing marks do not align, rotate the crankshaft clockwise again and align the timing marks.

       Table 6. Text in Illustration

       *1	Crankshaft Timing Gear Key	*2	Timing Mark
       *a	Toward Ceiling	*b	Timing Mark Position
       *c	Knock Pin Position	*d	Approximately 2°
       *e	Approximately 45°	*f	Approximately 16°
       *g	Approximately 18°	*h	Approximately 32°

28. Click here

    REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY LH

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29. Click here

    REMOVE CHAIN TENSIONER SLIPPER LH

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30. Click here

    REMOVE NO. 1 CHAIN VIBRATION DAMPER LH

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31. Click here

    REMOVE NO. 1 CHAIN SUB-ASSEMBLY LH

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32. Click here

    REMOVE NO. 3 CHAIN TENSIONER ASSEMBLY

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33. Click here

    REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY RH

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34. Click here

    REMOVE CHAIN TENSIONER SLIPPER RH

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35. Click here

    REMOVE NO. 1 CHAIN VIBRATION DAMPER RH

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36. Click here

    REMOVE NO. 1 CHAIN SUB-ASSEMBLY RH

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37. Click here

    REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY

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38. Click here

    REMOVE CRANKSHAFT TIMING GEAR KEY

    
    
    1. 

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

39. Click here

    REMOVE CAMSHAFT BEARING CAP LH

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40. Click here

    REMOVE NO. 3 CAMSHAFT SUB-ASSEMBLY

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41. Click here

    REMOVE NO. 4 CAMSHAFT SUB-ASSEMBLY

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42. Click here

    REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY LH

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43. Click here

    REMOVE CAMSHAFT BEARING CAP RH

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44. Click here

    REMOVE NO. 1 CAMSHAFT SUB-ASSEMBLY

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45. Click here

    REMOVE NO. 2 CAMSHAFT SUB-ASSEMBLY

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46. Click here

    REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY RH

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47. Click here

    REMOVE NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY

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48. Click here

    REMOVE VALVE LASH ADJUSTER ASSEMBLY

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49. Click here

    REMOVE VALVE STEM CAP

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50. Click here

    REMOVE CYLINDER HEAD SUB-ASSEMBLY LH

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51. Click here

    REMOVE NO. 2 CYLINDER HEAD GASKET

52. Click here

    REMOVE CYLINDER HEAD SUB-ASSEMBLY

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53. Click here

    REMOVE CYLINDER HEAD GASKET

54. Click here

    REMOVE CYLINDER BLOCK WATER JACKET SPACER

    
    
    1. 

       Remove the 2 cylinder block water jacket spacers from the cylinder block.

       Note:

       Be sure to remove the cylinder block water jacket spacers. Otherwise, they may fall and become damaged when the cylinder block is inverted.

55. Click here

    REMOVE OIL RETURN PIPE GASKET

    
    
    1. 

       Using a screwdriver, pry out the oil return pipe gasket.

       Table 7. Text in Illustration

       *1	Protective Tape

       Tip:

       Tape the screwdriver tip before use.

56. Click here

    REMOVE VENTILATION PIPE GASKET

    
    
    1. 

       Using a screwdriver, pry out the ventilation pipe gasket.

       Table 8. Text in Illustration

       *1	Protective Tape

       Tip:

       Tape the screwdriver tip before use.

57. Click here

    REMOVE NO. 1 HEAT EXCHANGER COVER

    
    
    1. 

       Remove the 12 bolts and 2 nuts.

       Table 9. Text in Illustration

       	Bolt
       	Nut

    2. 

       Remove the No. 1 heat exchanger cover by prying between the No. 1 heat exchanger cover and cylinder block with a screwdriver.

       Table 10. Text in Illustration

       *1	Protective Tape

       Tip:

       Tape the screwdriver tip before use.

58. Click here

    REMOVE NO. 2 OIL PAN SUB-ASSEMBLY

    
    
    1. 

       Remove the 14 bolts and 2 nuts.

       Table 11. Text in Illustration

       	Bolt
       	Nut

    2. 

       Insert the blade of an oil pan seal cutter between the oil pans. Cut through the applied sealer and remove the No. 2 oil pan.

       Note:

       Be careful not to damage the contact surfaces of the oil pans.

59. Click here

    REMOVE NO. 1 OIL PAN SUB-ASSEMBLY

    
    
    1. 

       Remove the 14 bolts and 2 nuts.

       Table 12. Text in Illustration

       	Bolt
       	Nut

       Tip:

       Be sure to clean the bolts and stud bolts and check the threads for cracks or other damage.

    2. 

       Remove the No. 1 oil pan by prying between the No. 1 oil pan and cylinder block with a screwdriver.

       Table 13. Text in Illustration

       *a	for LH Side
       *b	for RH Side

       Note:

       Be careful not to damage the contact surfaces of the cylinder block and No. 1 oil pan.

       Tip:

       Tape the screwdriver tip before use.

60. Click here

    REMOVE NO. 1 OIL PAN BAFFLE PLATE

    
    
    1. 

       Remove the 7 bolts and No. 1 oil pan baffle plate.

61. Click here

    REMOVE OIL STRAINER SUB-ASSEMBLY

    
    
    1. 

       Remove the 2 bolts, oil strainer and O-ring.

62. Click here

    REMOVE REAR ENGINE OIL SEAL RETAINER

    
    
    1. 

       Remove the 6 bolts and rear engine oil seal retainer.

    2. 

       Using a screwdriver, pry out the rear engine oil seal retainer.

       Tip:

       Tape the screwdriver tip before use.

63. Click here

    REMOVE REAR CRANKSHAFT OIL SEAL

    
    
    1. 

       Place the rear engine oil seal retainer on wooden blocks.

       Table 14. Text in Illustration

       *1	Wooden Block

    2. Using a screwdriver and hammer, tap out the rear crankshaft oil seal.

64. Click here

    REMOVE OIL DRAIN PIPE SUB-ASSEMBLY

    
    
    1. 

       Remove the bolt and oil drain pipe.

    2. Remove the O-ring.

65. Click here

    REMOVE RING PIN

    Note:

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

66. Click here

    REMOVE STUD BOLT

    Note:

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