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 (w/ Oil Cooler)

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  4. REMOVE OIL FILTER BRACKET (w/ Oil Cooler)

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  5. REMOVE OIL FILTER BRACKET (w/o Oil Cooler)

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  6. REMOVE OIL FILLER CAP SUB-ASSEMBLY

  7. REMOVE OIL FILLER CAP HOUSING


    1. A01WQAD

      Remove the 2 bolts, filler cap housing and gasket.

  8. REMOVE SPARK PLUG


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

  9. REMOVE VVT SENSOR


    1. A01WQR3

      LH:

      Remove the 2 bolts and 2 VVT sensors.

    2. A01WVVG

      RH:

      Remove the 2 bolts and 2 VVT sensors.

  10. REMOVE CAMSHAFT POSITION SENSOR


    1. A01WSCA

      Remove the bolt and camshaft position sensor.

  11. REMOVE CRANK POSITION SENSOR PROTECTOR

    A01WTB6

    1. Remove the 2 bolts and sensor protector.

  12. REMOVE CRANKSHAFT POSITION SENSOR


    1. A01WPLR

      Remove the bolt and crankshaft position sensor.

  13. REMOVE CAMSHAFT OIL CONTROL VALVE ASSEMBLY


    1. A01WWE6

      LH:

      Remove the 2 bolts and 2 oil control valves.

    2. A01WWKP

      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

    A01WRW8E18
    *1 Cylinder Head Cover Spacer
    *2 Gasket
    *3 Filter

    1. LH:

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

    2. A01WQG5E15
      *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

    A01WQYKE07
    *1 Tape
    *2 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.

      Tech Tips

      Tape the screwdriver tip before use.

      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.

  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. A01WWM8E06
      *1 Wooden Block

      Place the timing chain cover on wooden blocks.

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

      Tech Tips

      Tape the screwdriver tip before use.

      Note

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

  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.

      A01WTYXE11

  28. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY LH


    1. A01WW0SE07
      *1 Plunger
      *2 Stopper Plate

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

    2. A01WVOCE07
      *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. A01WPU7

      Remove the 2 bolts, chain tensioner and gasket.

  29. REMOVE NO. 1 CHAIN TENSIONER SLIPPER LH

    A01WQJ1

  30. REMOVE NO. 1 CHAIN VIBRATION DAMPER LH

    A01WUA0

    1. Remove the 2 bolts and chain vibration damper.

  31. REMOVE NO. 1 CHAIN SUB-ASSEMBLY LH

    A01WTCVE09
    *1 Push
    *2 Pin
    *3 Plunger

    1. 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. A01WQFAE09
      *1 Turn
      *2 Hold

      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. A01WVQAE07
      *1 Turn
      *2 Hold

      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

    A01WW6X

    1. Remove the 2 bolts and chain tensioner.

  33. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY RH


    1. A01WVOHE08
      *1 Plunger
      *2 Stopper Plate

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

    2. A01WWQEE07
      *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. A01WPYZ

      Remove the 2 bolts and chain tensioner.

  34. REMOVE NO. 1 CHAIN TENSIONER SLIPPER RH

    A01WWQ9

  35. REMOVE NO. 1 CHAIN VIBRATION DAMPER RH

    A01WTHB

    1. Remove the 2 bolts and vibration damper.

  36. REMOVE NO. 1 CHAIN SUB-ASSEMBLY RH

    A01WUDJE08
    *1 Push
    *2 Pin
    *3 Plunger

    1. 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. A01WVEQE01
      *1 Hold
      *2 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. A01WUIME07
      *1 Turn
      *2 Hold

      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

    A01WT5Q

    1. Remove the 2 bolts and chain tensioner.

  38. REMOVE CRANKSHAFT TIMING GEAR KEY

    A01WWIO

    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

    Click here

  48. REMOVE CYLINDER BLOCK WATER JACKET SPACER

    A01WT63

    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. A01WQYV

      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. A01WUOSE12
      *1 Nut

      Remove the 12 bolts and 2 nuts.

    2. A01WVEE

      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. Remove the engine oil level sensor Click here.

    2. A01WWK3E01
      *1 Nut

      Remove the 14 bolts and 2 nuts.

    3. A01WW53

      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. A01WWBLE14
      *1 Nut

      Remove the 14 bolts and 2 nuts.

      Tech Tips

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

    2. A01WQS0E02
      *1 LH Side:
      *2 RH Side:

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

      Tech Tips

      Tape the screwdriver tip before use.

      Note

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

  53. REMOVE NO. 1 OIL PAN BAFFLE PLATE


    1. A01WRY7

      Remove the 7 bolts and baffle plate.

  54. REMOVE OIL STRAINER SUB-ASSEMBLY


    1. A01WST2

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

  55. REMOVE ENGINE REAR OIL SEAL RETAINER


    1. A01WSXS

      Remove the 6 bolts and oil seal retainer.

    2. A01WPBD

      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. A01WSBW

      Remove the bolt and oil drain pipe.

    2. Remove the O-ring.

  57. REMOVE REAR CRANKSHAFT OIL SEAL


    1. A01WQV2E05
      *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.