ENGINE UNIT DISASSEMBLY

PROCEDURE


  1. REMOVE OIL FILLER CAP SUB-ASSEMBLY


    1. B0042S0

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

  2. REMOVE OIL FILLER CAP GASKET


    1. B0042QE

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

  3. REMOVE ENGINE COVER JOINT


    1. B0042S8

      Remove the 2 engine cover joints from the cylinder head cover sub-assembly.

  4. REMOVE SPARK PLUG

    Click here

  5. REMOVE CAMSHAFT POSITION SENSOR


    1. B0043HT

      Remove the 2 bolts and 2 camshaft position sensors from the cylinder head cover sub-assembly.

  6. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY


    1. B0043K0

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

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

  7. REMOVE CRANKSHAFT POSITION SENSOR


    1. B0042EP

      Remove the bolt and crankshaft position sensor.

  8. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY


    1. B0041MT

      Using a 24 mm deep socket wrench, remove the engine oil pressure switch assembly.

  9. REMOVE KNOCK CONTROL SENSOR


    1. B0042BQ

      Remove the bolt and knock control sensor.

  10. REMOVE ENGINE COOLANT TEMPERATURE SENSOR


    1. B0043HD

      Remove the engine coolant temperature sensor.

    2. Remove the gasket from the engine coolant temperature sensor.

  11. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY


    1. B00440Y

      Remove the 13 bolts, seal washer and cylinder head cover sub-assembly from the camshaft housing sub-assembly.

    2. B00422C

      Remove the 3 gaskets from the camshaft bearing cap.

      Note

      Be careful not to drop any of the gaskets into the engine when removing the cylinder head cover sub-assembly because the gaskets may stick to the cylinder head cover sub-assembly.

  12. REMOVE CYLINDER HEAD COVER GASKET


    1. B0042B0

      Remove the cylinder head cover gasket from the cylinder head cover sub-assembly.

  13. REMOVE SPARK PLUG TUBE GASKET


    1. B0041WS

      Pry up the 4 claws of the ventilation baffle plate.

      Note

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

    2. B0041XO

      Using a screwdriver as shown in the illustration, deform each spark plug tube gasket inwards and remove the 4 spark plug tube gaskets from the cylinder head cover sub-assembly.

      Tech Tips


      • If the cylinder head cover is damaged, smooth the surface with 400-grit sandpaper.

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

      Note


      • As much as possible prevent the spark plug tube gaskets from being deformed.

        The removed spark plug tube gaskets will be used when reinstalling the new spark plug tube gaskets.

      • Do not damage the cylinder head cover sub-assembly.

      • Make sure not to damage the spark plug tube gasket and cylinder head cover sub-assembly when cool in joint area.


      1. B0044BWC01
        *a Before cutting off
        *b After cutting off
        B0042RQ Area to be cut off

        Using a cutter, cut off the sealing part of the removed plug tube gasket.

  14. REMOVE OIL FILTER CAP ASSEMBLY

    Click here

  15. REMOVE WATER INLET HOUSING


    1. B0044QT

      Remove the 3 bolts, gasket and water inlet housing.

  16. SET NO. 1 CYLINDER TO TDC/COMPRESSION


    1. B0042Q0C01
      *a Timing Mark
      *b Timing Notch

      Turn the crankshaft pulley until its timing notch and timing mark "0" of the timing chain cover sub-assembly are aligned.

    2. Check that timing marks on the camshaft timing exhaust gear assembly and camshaft timing gear assembly are facing upward as shown in the illustration.

      If not, turn the crankshaft 1 complete revolution (360°) and align the marks as above.

  17. REMOVE CRANKSHAFT PULLEY

    Click here

  18. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY


    1. B0042D1

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

      Note

      Do not turn the crankshaft without the No. 1 chain tensioner assembly installed.

  19. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY

    Click here

  20. REMOVE TIMING CHAIN COVER OIL SEAL


    1. B0044YPC04
      *a Wooden Block
      *b Protective Tape

      Using a screwdriver and hammer, remove the timing chain cover oil seal.

      Note

      Be careful not to damage the timing chain cover sub-assembly.

      Tech Tips

      Tape the screwdriver tip before use.

  21. REMOVE NO. 1 GENERATOR BRACKET


    1. B004228

      Remove the 4 bolts and No. 1 generator bracket.

  22. REMOVE NO. 2 CHAIN VIBRATION DAMPER


    1. B0041T6

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

  23. REMOVE CHAIN TENSIONER SLIPPER


    1. B004217

      Remove the chain tensioner slipper.

  24. REMOVE NO. 1 CHAIN VIBRATION DAMPER


    1. B0043Y0

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

  25. REMOVE CHAIN SUB-ASSEMBLY


    1. B0042M6C01
      *a Turn
      *b Place the Chain Sub-assembly on the Camshaft Timing Gear Assembly
      *c Loosen the Chain Sub-assembly

      Hold the hexagonal portion of the camshaft with a wrench and turn the camshaft timing gear assembly counterclockwise to loosen the chain sub-assembly between the camshaft timing gears.

    2. With the chain sub-assembly loosened, release the chain sub-assembly from the camshaft timing gear assembly and place it on the camshaft timing gear assembly.

      Tech Tips

      Be sure to release the chain sub-assembly from the sprocket completely.

    3. Turn the camshaft clockwise to return it to the original position and remove the chain sub-assembly.

  26. REMOVE CRANKSHAFT TIMING SPROCKET

    Click here

  27. REMOVE NO. 2 CHAIN SUB-ASSEMBLY

    Click here

  28. REMOVE NO. 1 CRANKSHAFT POSITION SENSOR PLATE


    1. B0043IK

      Remove the No. 1 crankshaft position sensor plate.

  29. REMOVE CRANKSHAFT TIMING GEAR KEY


    1. B0043F9C11
      *a Protective Tape

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

      Tech Tips

      Tape the screwdriver tip before use.

  30. REMOVE NO. 1 TAPER SCREW PLUG


    1. B00454C

      Remove the No. 1 taper screw plug.

  31. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY


    1. Check the lock of the camshaft timing gear assembly.

    2. Release the lock pin.

      Note

      Before removing the camshaft timing gear assembly, make sure that the lock pin has been released.


      1. B00422KC02
        *a Adhesive Tape Sealing Area
        *b Prick a Hole
        *c Adhesive Tape

        After cleaning the VVT oil hole on the intake side of the No. 1 camshaft bearing cap, completely seal the oil hole with adhesive tape or equivalent as shown in the illustration to prevent air from leaking.

        Note

        Be sure to cover the oil hole completely because air leaks due to insufficient sealing will prevent the lock pin from being released.

      2. Prick a hole in the tape covering the oil hole as shown in the illustration. (Procedure A)

      3. B0043GG

        Apply approximately 150 kPa (1.5 kgf/cm2, 22 psi) of air pressure to the hole pricked in procedure A to release the lock pin.

        Note


        • If air leaks out, reattach adhesive tape.

        • Cover the oil hole with a piece of cloth when applying air pressure to prevent oil from spraying.

        • Do not lock the camshaft timing gear assembly. If it is locked, release the lock pin again.

        Tech Tips


        • Depending on the air pressure applied, the camshaft timing gear assembly may turn in the advance direction without assistance by hand.

        • If enough air pressure cannot be applied because of air leakage from the port, releasing the lock pin may be difficult.

      4. Remove the adhesive tape from the No. 1 camshaft bearing cap.

    3. B00445GC02
      *1 Bolt
      *a Do not remove

      Remove the bolt while holding the hexagonal portion of the camshaft, and then remove the camshaft timing gear assembly.

      Note


      • Do not remove the other 4 bolts.

      • Keep the camshaft timing exhaust gear assembly horizontal while removing it from the camshaft.

  32. REMOVE CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY


    1. B0041XUC01
      *1 Bolt
      *a Do not remove

      Remove the bolt while holding the hexagonal portion of the No. 2 camshaft, then remove the camshaft timing exhaust gear assembly.

      Note


      • Do not remove the other 4 bolts.

      • Keep the camshaft timing exhaust gear assembly horizontal while removing it from the No. 2 camshaft.

  33. REMOVE CAMSHAFT BEARING CAP


    1. B0042HWN03

      Uniformly loosen and remove the 10 bearing cap bolts in the order shown in the illustration.

    2. B0041UGN02

      Uniformly loosen and remove the 15 bearing cap bolts in the order shown in the illustration.

      Note

      Uniformly loosen the bolts while keeping the camshaft level.

    3. Remove the 5 camshaft bearing caps.

      Tech Tips

      Arrange the removed parts in the correct order.

  34. REMOVE CAMSHAFT


    1. B0043ZB

      Remove the camshaft.

  35. REMOVE NO. 2 CAMSHAFT


    1. B0041R2

      Remove the No. 2 camshaft.

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


    1. B0042ON

      Remove the 16 No. 1 valve rocker arm sub-assemblies.

      Tech Tips

      Arrange the removed parts in the correct order.

  37. REMOVE VALVE LASH ADJUSTER ASSEMBLY


    1. B00437O

      Remove the 16 valve lash adjuster assemblies from the cylinder head sub-assembly.

      Tech Tips

      Arrange the removed parts in the correct order.

  38. REMOVE OIL CONTROL VALVE FILTER


    1. B0044NL

      Remove the oil control valve filter.

  39. REMOVE NO. 1 CAMSHAFT BEARING

    Click here

  40. REMOVE NO. 2 CAMSHAFT BEARING


    1. B0042QR

      Remove the 2 No. 2 camshaft bearings from the camshaft housing sub-assembly.

      Note

      Arrange the removed parts in the correct order.

  41. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY


    1. B0043IJ

      Remove the 2 bolts.

    2. B0043PPC06
      *a Protective Tape

      Remove the camshaft housing sub-assembly by prying between the cylinder head sub-assembly and camshaft housing sub-assembly with a screwdriver.

      Note

      Be careful not to damage the contact surfaces of the cylinder head sub-assembly and camshaft housing sub-assembly.

      Tech Tips

      Tape the screwdriver tip before use.

  42. REMOVE CYLINDER HEAD SUB-ASSEMBLY

    Click here

  43. REMOVE CYLINDER HEAD GASKET

    Click here

  44. REMOVE PCV VALVE (VENTILATION VALVE SUB-ASSEMBLY)

    Click here

  45. REMOVE OIL PAN DRAIN PLUG


    1. B0042MN

      Remove the oil pan drain plug and gasket.

  46. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY

    Click here

  47. REMOVE OIL PUMP ASSEMBLY

    Click here

  48. REMOVE REAR ENGINE OIL SEAL

    Click here

  49. REMOVE STIFFENING CRANKCASE ASSEMBLY


    1. B0044D6

      Uniformly loosen and remove the 11 bolts.

    2. B00424PC05
      *a Protective Tape

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

      Note

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

      Tech Tips

      Tape the screwdriver tip before use.

  50. REMOVE RING PIN

    Note

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


    1. B0042A5

      Remove the 2 ring pins from the stiffening crankcase assembly.

  51. REMOVE STUD BOLT

    Note

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


    1. B00451G

      for Stiffening crankcase assembly:


      1. Using an E5 "TORX" socket wrench, remove the 2 stud bolts from the stiffening crankcase assembly.

    2. B0044IH

      for Water inlet housing:


      1. Using an E5 "TORX" socket wrench, remove the 2 stud bolts from the water inlet housing.