ENGINE UNIT DISASSEMBLY

PROCEDURE


  1. REMOVE OIL PRESSURE SENDER GAUGE ASSEMBLY

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  2. REMOVE OIL FILTER ELEMENT

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  3. REMOVE NO. 1 OIL COOLER BRACKET

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  4. REMOVE OIL FILTER BRACKET

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  5. REMOVE OIL FILLER CAP SUB-ASSEMBLY

  6. REMOVE OIL FILLER CAP HOUSING


    1. B001WB9

      Remove the 2 bolts, filler cap housing and gasket.

  7. REMOVE SPARK PLUG


    1. Using a 16 mm plug wrench, remove the 8 spark plugs.

  8. REMOVE VVT SENSOR


    1. B001VRI

      LH:

      Remove the 2 bolts and 2 VVT sensors.

    2. B001X4U

      RH:

      Remove the 2 bolts and 2 VVT sensors.

  9. REMOVE CAMSHAFT POSITION SENSOR


    1. B001YE9

      Remove the bolt and camshaft position sensor.

  10. REMOVE CRANK POSITION SENSOR PROTECTOR

    B001Y2W

    1. Remove the 2 bolts and sensor protector.

  11. REMOVE CRANKSHAFT POSITION SENSOR


    1. B001ZRB

      Remove the bolt and crankshaft position sensor.

  12. REMOVE ENGINE OIL LEVEL SENSOR

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  13. REMOVE CAMSHAFT OIL CONTROL VALVE ASSEMBLY


    1. B001W1D

      LH:

      Remove the 2 bolts and 2 oil control valves.

    2. B001W28

      RH:

      Remove the 2 bolts and 2 oil control valves.

  14. REMOVE WATER PUMP PULLEY

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  15. REMOVE NO. 1 IDLER PULLEY SUB-ASSEMBLY

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  16. REMOVE FLUID COUPLING BRACKET

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  17. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY

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  18. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH

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  19. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY RH

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  20. REMOVE OIL CONTROL VALVE FILTER


    1. B00205YE15
      Text in Illustration
      *1 Cylinder Head Cover Spacer
      *2 Gasket
      *3 Filter

      LH:

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

    2. B001VYME12
      Text in Illustration
      *1 Cylinder Head Cover Spacer
      *2 Gasket
      *3 Filter

      RH:

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

  21. REMOVE SPARK PLUG TUBE GASKET

    B001W69E02
    Text in Illustration
    *1 Tape
    B001XPG Pry

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

    2. Using a screwdriver, pry out the gaskets.

      Note


      • Be careful not to damage the cylinder head cover.

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

      Tech Tips

      Tape the screwdriver tip before use.

  22. REMOVE CRANKSHAFT PULLEY

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  23. REMOVE WATER PUMP ASSEMBLY

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  24. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY

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  25. REMOVE WATER INLET PIPE

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  26. REMOVE FRONT CRANKSHAFT OIL SEAL


    1. B00201JE05
      Text in Illustration
      *1 Wooden Block

      Place the timing chain cover on wooden blocks.

    2. Using a screwdriver and wooden block, pry out the oil seal.

      Note

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

      Tech Tips

      Tape the screwdriver tip before use.

  27. SET NO. 1 CYLINDER TO TDC/COMPRESSION


    1. Temporarily install the crankshaft pulley bolt.

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

      Tech Tips

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

      B001WVYE10
      Text in Illustration
      *1 Timing Mark *2 Timing Mark Position
      *3 Knock Pin Position *4 Key
      *a Toward Ceiling *b Approximately 2°
      *c Approximately 45° *d Approximately 16°
      *e Approximately 18° *f Approximately 32°

  28. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY LH


    1. B001ZFRE06
      Text in Illustration
      *1 Plunger
      *2 Stopper Plate

      Move the stopper plate clockwise to release the lock, and push the plunger deep into the tensioner.

    2. B001YVKE06
      Text in Illustration
      *1 Plunger
      *2 Stopper Plate

      Move the stopper plate counterclockwise to set the lock, and insert a hexagon wrench into the stopper plate hole.

    3. B001WT2

      Remove the 2 bolts, chain tensioner and gasket.

  29. REMOVE NO. 1 CHAIN TENSIONER SLIPPER LH

    B001YG8

  30. REMOVE NO. 1 CHAIN VIBRATION DAMPER LH

    B001XFQ

    1. Remove the 2 bolts and chain vibration damper.

  31. REMOVE NO. 1 CHAIN SUB-ASSEMBLY LH


    1. B001X6IE08
      Text in Illustration
      *1 Pin
      *2 Plunger
      *a Push

      While pushing down the No. 3 chain tensioner, insert a pin of 1.0 mm (0.0394 in.) into the hole to fix it in place.

    2. B001VVCE08
      Text in Illustration
      *a Hold
      B001XPG Turn

      Hold the hexagonal portion of the camshaft with a wrench and loosen the bolt.

      Note


      • Be careful not to damage the cylinder head with the wrench.

      • Do not disassemble the camshaft timing gear.

    3. B001XNYE02
      Text in Illustration
      *a Hold
      B001XPG Turn

      Hold the hexagonal portion of the camshaft with a wrench and loosen the bolt.

      Note

      Be careful not to damage the cylinder head with the wrench.

    4. Remove the 2 bolts. Then with the No. 1 and No. 2 chains still connected to the gears, remove the camshaft timing gear, camshaft timing exhaust gear and crankshaft timing sprocket LH.

    5. Remove the No. 1 and No. 2 chains from the gears.

  32. REMOVE NO. 3 CHAIN TENSIONER ASSEMBLY

    B001YZU

    1. Remove the 2 bolts and chain tensioner.

  33. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY RH


    1. B001Z79E07
      Text in Illustration
      *1 Plunger
      *2 Stopper Plate

      Move the stopper plate clockwise to release the lock, and push the plunger deep into the tensioner.

    2. B001VS5E06
      Text in Illustration
      *1 Plunger
      *2 Stopper Plate

      Move the stopper plate counterclockwise to set the lock, and insert a hexagon wrench into the stopper plate hole.

    3. B001YQN

      Remove the 2 bolts and chain tensioner.

  34. REMOVE NO. 1 CHAIN TENSIONER SLIPPER RH

    B001YMI

  35. REMOVE NO. 1 CHAIN VIBRATION DAMPER RH

    B001X0S

    1. Remove the 2 bolts and vibration damper.

  36. REMOVE NO. 1 CHAIN SUB-ASSEMBLY RH


    1. B001WLYE07
      Text in Illustration
      *1 Pin
      *2 Plunger
      *a Push

      While raising up the No. 2 chain tensioner, insert a pin of 1.0 mm (0.0394 in.) into the hole to fix it in place.

    2. B001X4OE02
      Text in Illustration
      *a Hold
      B001XPG Turn

      Hold the hexagonal portion of the camshaft with a wrench and loosen the bolt.

      Note


      • Be careful not to damage the cylinder head with the wrench.

      • Do not disassemble the camshaft timing gear.

    3. B001XBEE02
      Text in Illustration
      *a Hold
      B001XPG Turn

      Hold the hexagonal portion of the camshaft with a wrench and loosen the bolt.

      Note

      Be careful not to damage the cylinder head with the wrench.

    4. Remove the 2 bolts. Then with the No. 1 and No. 2 chains still connected to the gears, remove the camshaft timing gear, camshaft timing exhaust gear and crankshaft timing sprocket RH.

    5. Remove the No. 1 and No. 2 chains from the gears.

  37. REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY

    B001W5Q

    1. Remove the 2 bolts and chain tensioner.

  38. REMOVE CRANKSHAFT TIMING GEAR KEY

    B001YKG

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

  39. REMOVE CAMSHAFT BEARING CAP LH

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  40. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY LH

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  41. REMOVE CAMSHAFT BEARING CAP RH

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  42. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY RH

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


    1. Remove the 32 valve rocker arms from the cylinder heads.

      Tech Tips

      Arrange the removed parts in the correct order.

  44. REMOVE VALVE LASH ADJUSTER ASSEMBLY


    1. Remove the 32 valve lash adjusters from the cylinder heads.

      Tech Tips

      Arrange the removed parts in the correct order.

  45. REMOVE VALVE STEM CAP


    1. Remove the 32 valve stem caps from the cylinder heads.

      Tech Tips

      Arrange the removed parts in the correct order.

  46. REMOVE CYLINDER HEAD SUB-ASSEMBLY LH

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  47. REMOVE CYLINDER HEAD SUB-ASSEMBLY RH

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  48. REMOVE CYLINDER BLOCK WATER JACKET SPACER

    B001YS1

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

      Note

      Be sure to remove the water jacket spacers. If not, they may fall and become damaged when the cylinder block is inverted.

  49. REMOVE VENTILATION PIPE GASKET


    1. B001XU3

      Using a screwdriver, pry out the ventilation pipe gasket.

      Tech Tips

      Tape the screwdriver tip before use.

  50. REMOVE NO. 1 HEAT EXCHANGER COVER


    1. B001VRD

      Remove the 12 bolts and 2 nuts.

      Text in Illustration
      B001XPG Bolt
      B001WGT Nut
    2. B001YF8

      Remove the heat exchanger by prying between the heat exchanger and cylinder block with a screwdriver.

      Tech Tips

      Tape the screwdriver tip before use.

  51. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY


    1. B001WRZ

      Remove the 14 bolts and 2 nuts.

      Text in Illustration
      B001XPG Bolt
      B001WGT Nut
    2. B001Z2R

      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.

  52. REMOVE NO. 1 OIL PAN SUB-ASSEMBLY


    1. B001YCV

      Remove the 14 bolts and 2 nuts.

      Text in Illustration
      B001XPG Bolt
      B001WGT Nut

      Tech Tips

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

    2. B00207KE03
      Text in Illustration
      *A LH Side
      *B RH Side

      Remove the oil pan by prying between the oil pan and cylinder block with a screwdriver.

      Note

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

      Tech Tips

      Tape the screwdriver tip before use.

  53. REMOVE NO. 1 OIL PAN BAFFLE PLATE


    1. B001WXK

      Remove the 7 bolts and baffle plate.

  54. REMOVE OIL STRAINER SUB-ASSEMBLY


    1. B001ZDC

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

  55. REMOVE ENGINE REAR OIL SEAL RETAINER


    1. B001YOI

      Remove the 6 bolts and oil seal retainer.

    2. B001XRN

      Using a screwdriver, pry out the oil seal retainer.

      Tech Tips

      Tape the screwdriver tip before use.

  56. REMOVE OIL DRAIN PIPE SUB-ASSEMBLY


    1. B001XJU

      Remove the bolt and oil drain pipe.

    2. Remove the O-ring.

  57. REMOVE REAR CRANKSHAFT OIL SEAL


    1. B001VPQE02
      Text in Illustration
      *1 Wooden Block

      Place the oil seal retainer on wooden blocks.

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

  58. REMOVE RING PIN

    Note

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

  59. REMOVE STUD BOLT

    Note

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