ENGINE UNIT DISASSEMBLY

PROCEDURE


  1. REMOVE OIL FILLER CAP SUB-ASSEMBLY


    1. A002PXF

      Remove the oil filler cap.

  2. REMOVE OIL FILLER CAP GASKET


    1. A002MXC

      Remove the oil filler cap gasket.

  3. REMOVE ENGINE COVER JOINT


    1. A002NL9

      Remove the 2 engine cover joints.

  4. REMOVE SPARK PLUG

    Click here

  5. REMOVE CAMSHAFT POSITION SENSOR


    1. A002Q82

      Remove the 2 bolts and 2 camshaft position sensors.

  6. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY


    1. A002MXY

      Remove the 2 bolts, wire harness bracket and 2 camshaft timing oil control valves.

    2. Remove the 2 O-rings from the camshaft timing oil control valves.

  7. REMOVE CRANKSHAFT POSITION SENSOR


    1. A002PUE

      Remove the bolt and crankshaft position sensor.

  8. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY

    Click here

  9. REMOVE KNOCK SENSOR


    1. A002LUO

      Remove the bolt and knock sensor.

  10. REMOVE ENGINE COOLANT TEMPERATURE SENSOR


    1. A002OFBE04

      Using SST, remove the engine coolant temperature sensor and gasket.

      SST
      09817-33190

  11. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A002MJJ

      Remove the 13 bolts, seal washer and cylinder head cover.

    2. A002PHQ

      Remove the 3 gaskets from the camshaft bearing cap.

      Note

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

  12. REMOVE CYLINDER HEAD COVER GASKET


    1. A002NQ1

      Remove the cylinder head cover gasket.

  13. REMOVE SPARK PLUG TUBE GASKET


    1. A002PVF

      Pry up the 4 claws of the ventilation baffle plate.

      Note

      Do not deform the claws of the baffle plate more than necessary.

    2. Remove the 4 gaskets from the cylinder head cover.

      Tech Tips

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

      Note

      Be careful not to damage the cylinder head cover.

  14. REMOVE OIL FILTER CAP ASSEMBLY

    Click here

  15. SET NO. 1 CYLINDER TO TDC/COMPRESSION

    Click here

  16. REMOVE CRANKSHAFT PULLEY

    Click here

  17. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY

    Click here

  18. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY

    Click here

  19. REMOVE TIMING CHAIN COVER OIL SEAL

    Click here

  20. REMOVE ENGINE MOUNTING BRACKET STUD BOLT

    Note

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

  21. REMOVE WATER INLET HOUSING STUD BOLT

    Note

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

  22. REMOVE WATER INLET HOUSING


    1. A002M15

      Remove the 3 bolts, water inlet housing and gasket.

  23. REMOVE NO. 1 GENERATOR BRACKET


    1. A002MPQ

      Remove the 4 bolts and generator bracket.

  24. REMOVE CHAIN TENSIONER SLIPPER

    Click here

  25. REMOVE NO. 1 CHAIN VIBRATION DAMPER

    Click here

  26. REMOVE CHAIN SUB-ASSEMBLY

    Click here

  27. REMOVE CRANKSHAFT TIMING SPROCKET

    Click here

  28. REMOVE NO. 2 CHAIN SUB-ASSEMBLY

    Click here

  29. REMOVE NO. 1 CRANKSHAFT POSITION SENSOR PLATE


    1. A002N2M

      Remove the crankshaft position sensor plate.

  30. REMOVE CRANKSHAFT TIMING GEAR KEY


    1. A002NPWE02
      Text in Illustration
      *1 Protective Tape

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

      Tech Tips

      Tape the screwdriver tip before use.

      Note

      Be careful not to damage the crankshaft.

  31. INSPECT CAMSHAFT TIMING GEAR ASSEMBLY

    Click here

  32. INSPECT CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY

    Click here

  33. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY

    Click here

  34. REMOVE CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY

    Click here

  35. REMOVE VALVE ROCKER ARM LOST MOTION DAMPER SUB-ASSEMBLY

    Click here

  36. INSTALL VALVE ROCKER ARM LOST MOTION DAMPER SUB-ASSEMBLY

    Click here

  37. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY

    Click here

  38. REMOVE CONTINUOUSLY VARIABLE VALVE LIFT CONTROLLER ASSEMBLY


    1. A002QVL

      Using a screwdriver, slide the control actuator clip from the control actuator connector.

      Note

      Slide only the upper part of the control actuator clip, as the straight pin may fall if the control actuator clip is completely removed.

    2. A002NSA

      Remove the bolt.

    3. A002NSN

      Using a screwdriver, lightly pry the control actuator connector to make a space between the continuously variable valve lift controller and camshaft housing.

      Note


      • Do not forcefully pry the control actuator connector.

      • Do not damage the camshaft housing or camshaft bearing cap.

    4. A002QZB

      Using a magnet hand, remove the straight pin from the control actuator connector.

      Tech Tips

      The straight pin can be removed by utilizing the space between the continuously variable valve lift controller and camshaft housing to move the continuously variable valve lift controller so that there is no load on the straight pin.

    5. A002N5JE01
      Text in Illustration
      *1 Continuously Variable Valve Lift Controller Assembly
      *2 Valve Lift Control Actuator Connector
      *3 O-Ring

      Remove the continuously variable valve lift controller from the camshaft housing.

    6. Remove the O-ring from the continuously variable valve lift controller.

      Note

      The O-ring may remain on the camshaft housing side. Be sure to always remove it.

    7. Remove the valve lift control actuator connector from the valve rocker shaft.

      Tech Tips

      There are two types of valve lift control actuator connectors. One type is removed by rotating the connector, and the other type can be removed without being rotated.

  39. REMOVE CAMSHAFT HOUSING STUD BOLT

    Note

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

  40. REMOVE CAMSHAFT HOUSING STRAIGHT PIN

    Note

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

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


    1. A002LOK

      Remove the 16 valve rocker arms.

      Tech Tips

      Arrange the removed parts in the correct order.

  42. REMOVE VALVE LASH ADJUSTER ASSEMBLY


    1. A002QVQ

      Remove the 16 valve lash adjusters from the cylinder head.

      Tech Tips

      Arrange the removed parts in the correct order.

  43. REMOVE VALVE STEM CAP


    1. A002QCE

      Remove the 16 valve stem caps.

      Tech Tips

      Arrange the removed parts in the correct order.

  44. REMOVE CYLINDER HEAD SUB-ASSEMBLY

    Click here

  45. REMOVE CYLINDER HEAD GASKET

    Click here

  46. REMOVE VENTILATION VALVE SUB-ASSEMBLY

    Click here

  47. REMOVE OIL PAN DRAIN PLUG


    1. A002QPM

      Remove the drain plug and gasket.

  48. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY

    Click here

  49. REMOVE OIL PUMP ASSEMBLY

    Click here

  50. REMOVE STIFFENING CRANKCASE ASSEMBLY


    1. A002OSP

      Uniformly loosen and remove the 11 bolts.

    2. A002MIYE13
      Text in Illustration
      *1 Protective Tape

      Using a screwdriver, remove the stiffening crankcase by prying between the stiffening crankcase and cylinder block.

      Tech Tips

      Tape the screwdriver tip before use.

      Note

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

  51. REMOVE NO. 1 TAPER SCREW PLUG


    1. A002QKQ

      Remove the 2 No. 1 taper screw plugs.

  52. REMOVE STIFFENING CRANKCASE STUD BOLT

    Note

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

  53. REMOVE STIFFENING CRANKCASE RING PIN

    Note

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

  54. REMOVE ENGINE REAR OIL SEAL


    1. A002MR8

      Remove the engine rear oil seal from the cylinder block.