ENGINE UNIT DISASSEMBLY

PROCEDURE


  1. REMOVE NO. 4 WATER BY-PASS PIPE


    1. A000NITE03
      Text in Illustration
      *1 No. 4 Water By-pass Pipe
      *2 No. 9 Water By-pass Hose
      *3 No. 7 Water By-pass Hose
      *4 No. 8 Water By-pass Hose

      Slide the clip and disconnect the No. 9 water by-pass hose from the cylinder head sub-assembly.

    2. Slide the 2 clips and disconnect the No. 7 water by-pass hose and No. 8 water by-pass hose from the oil cooler assembly.

    3. Remove the 2 bolts and No. 4 water by-pass pipe.

  2. REMOVE SPARK PLUG

    Click here

  3. REMOVE KNOCK CONTROL SENSOR

    Click here

  4. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY

    Click here

  5. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY

    Click here

  6. REMOVE VVT SENSOR

    Click here

  7. REMOVE PCV VALVE SUB-ASSEMBLY


    1. A000O8C

      Using a 19 mm deep socket wrench, remove the PCV valve sub-assembly.

  8. REMOVE OIL FILLER CAP SUB-ASSEMBLY


    1. Remove the oil filler cap sub-assembly from the cylinder head cover sub-assembly.

  9. REMOVE OIL FILLER CAP GASKET


    1. Remove the oil filler cap gasket from the oil filler cap sub-assembly.

  10. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY

    Click here

  11. REMOVE PCV CASE SUB-ASSEMBLY


    1. A000NCK

      Remove the gasket from the PCV case sub-assembly.

    2. A000O68

      Remove the 2 bolts and PCV case sub-assembly from the cylinder head cover sub-assembly.

    3. A000QA9E05
      Text in Illustration
      *1 O-ring

      Remove the O-ring from the PCV case sub-assembly.

  12. REMOVE SPARK PLUG TUBE GASKET


    1. A000T5GE02
      Text in Illustration
      *a Protective Tape

      Using a screwdriver, pry out the 4 spark plug tube gaskets.

      Note

      Be careful not to damage the cylinder head cover sub-assembly.

      Tech Tips

      Tape the screwdriver tip before use.

  13. REMOVE CRANKSHAFT POSITION SENSOR

    Click here

  14. REMOVE CRANKSHAFT PULLEY ASSEMBLY

    Click here

  15. REMOVE TIMING CHAIN COVER ASSEMBLY

    Click here

  16. REMOVE TIMING CHAIN COVER PLATE


    1. A000RUV

      Remove the 4 bolts, timing chain cover plate and No. 1 timing belt cover gasket from the timing chain cover assembly.

  17. REMOVE TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL

    Click here

  18. SET NO. 1 CYLINDER TO TDC/COMPRESSION


    1. Temporarily install the crankshaft pulley set bolt.

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

      A000OBIE03
      Text in Illustration
      *1 Crankshaft Pulley Set Crankshaft Key - -
      *a Timing Mark *b Identification Groove
      *c Approximately 7° *d Approximately 32°

      Tech Tips


      • The camshaft timing gear assembly and the camshaft timing exhaust gear assembly have both timing marks and identification grooves. Use the timing marks for alignment.

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

    3. Remove the crankshaft pulley set bolt.

  19. REMOVE TIMING CHAIN GUIDE


    1. A000PD7

      Remove the bolt and timing chain guide.

  20. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY


    1. A000QR0E03
      Text in Illustration
      *a Stopper Plate
      *b Plunger

      Allow the plunger to extend slightly, and then rotate the stopper plate counterclockwise to release the lock. Once the lock is released, push the plunger into the tensioner.

    2. A000NJTE03
      Text in Illustration
      *a Pin

      Move the stopper plate clockwise to set the lock, and insert a pin into the stopper plate hole.

    3. A000S3W

      Remove the 2 bolts, No. 1 chain tensioner assembly and chain tensioner gasket.

  21. REMOVE CHAIN TENSIONER SLIPPER


    1. A000OK9

      Remove the bolt and chain tensioner slipper.

  22. REMOVE NO. 1 CHAIN VIBRATION DAMPER


    1. A000Q2C

      Remove the 2 bolts and No. 1 chain vibration damper.

  23. REMOVE CHAIN SUB-ASSEMBLY


    1. Remove the chain sub-assembly.

  24. REMOVE CRANKSHAFT TIMING GEAR OR SPROCKET


    1. A000SCR

      Remove the crankshaft timing gear or sprocket from the crankshaft.

  25. REMOVE CRANKSHAFT PULLEY SET CRANKSHAFT KEY


    1. A000OKCE03
      Text in Illustration
      *a Protective Tape

      Using a screwdriver, remove the 2 crankshaft pulley set crankshaft keys from the crankshaft.

      Tech Tips

      Tape the screwdriver tip before use.

  26. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY

    Click here

  27. REMOVE CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY

    Click here

  28. REMOVE OIL PIPE SUB-ASSEMBLY


    1. A000RED

      Remove the bolt and oil pipe sub-assembly from the No. 4 camshaft bearing cap.

  29. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY

    Click here

  30. REMOVE CAMSHAFT BEARING CAP

    Click here

  31. REMOVE OIL CONTROL VALVE FILTER

    Click here

  32. REMOVE NO. 1 CAMSHAFT BEARING

    Click here

  33. REMOVE CAMSHAFT

    Click here

  34. REMOVE NO. 2 CAMSHAFT

    Click here

  35. REMOVE NO. 2 CAMSHAFT BEARING

    Click here

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

    Click here

  37. REMOVE VALVE LASH ADJUSTER ASSEMBLY

    Click here

  38. REMOVE VALVE STEM CAP

    Click here

  39. REMOVE CYLINDER HEAD SUB-ASSEMBLY

    Click here

  40. REMOVE CYLINDER HEAD GASKET

    Click here

  41. REMOVE CYLINDER BLOCK WATER JACKET SPACER


    1. A000ODG

      Remove the cylinder block water jacket spacer from the cylinder block sub-assembly.

      Note

      Be sure to remove the water jacket spacer. If it is not removed, it may fall and become damaged when the cylinder block sub-assembly is inverted.

  42. REMOVE OIL FILTER CAP ASSEMBLY

    Click here

  43. REMOVE ENGINE OIL LEVEL SENSOR

    Click here

  44. REMOVE OIL COOLER ASSEMBLY

    Click here

  45. REMOVE OIL PAN DRAIN PLUG


    1. Remove the oil pan drain plug and gasket from the oil pan sub-assembly.

  46. REMOVE OIL PAN SUB-ASSEMBLY


    1. A000QZA

      Remove the 11 bolts and 2 nuts.

      Text in Illustration
      B002B6O Bolt
      B002BBR Nut
    2. A000T4ME07
      Text in Illustration
      *a Oil Pan Seal Cutter

      Insert the blade of an oil pan seal cutter between the oil pan sub-assembly and stiffening crankcase assembly, cut off the applied sealer and remove the oil pan sub-assembly.

      Note


      • Be careful not to damage the contact surface of the stiffening crankcase assembly and oil pan sub-assembly.

      • Be careful not to damage the oil pan sub-assembly flange.

      Tech Tips

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

  47. REMOVE OIL STRAINER SUB-ASSEMBLY


    1. A000ONQ

      Remove the 3 bolts, oil strainer sub-assembly and gasket.

  48. REMOVE NO. 1 OIL PAN BAFFLE PLATE


    1. A000ODK

      Remove the 4 bolts and No. 1 oil pan baffle plate.

  49. REMOVE ENGINE BALANCER ASSEMBLY


    1. A000O5O

      Remove the 5 bolts and engine balancer assembly.

      Note

      Do not disassemble the engine balancer assembly.

  50. REMOVE STIFFENING CRANKCASE ASSEMBLY


    1. A000SZJ

      Remove the 7 bolts.

    2. A000Q38E02
      Text in Illustration
      *a LH Side
      *b RH Side

      Using a screwdriver, remove the stiffening crankcase assembly by prying between the stiffening crankcase assembly and cylinder block sub-assembly at the places shown in the illustration.

      Note


      • Do not pry section A in the illustration. Otherwise, the stiffening case assembly may be damaged.

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

      Tech Tips

      Tape the screwdriver tip before use.

  51. REMOVE REAR ENGINE OIL SEAL


    1. A000RLC

      Remove the rear engine oil seal from the cylinder block sub-assembly.

  52. REMOVE STUD BOLT

    Note

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

  53. REMOVE CYLINDER HEAD SUB-ASSEMBLY

    Note

    If a ring pin is deformed or damaged, replace it.

  54. REMOVE STRAIGHT PIN

    Note

    If a straight pin is deformed or damaged, replace it.