ENGINE UNIT DISASSEMBLY

PROCEDURE


  1. REMOVE OIL FILLER CAP SUB-ASSEMBLY


    1. A01SFPA

      Remove the oil filler cap sub-assembly.

  2. REMOVE OIL FILLER CAP GASKET


    1. A01SFM9

      Remove the oil filler cap gasket.

  3. REMOVE ENGINE COVER JOINT BOLT


    1. A01SF9W

      Remove the 3 engine cover joint bolts.

  4. REMOVE WIRING HARNESS CLAMP BRACKET


    1. A01SF7Y

      Remove the bolt and wiring harness clamp bracket.

  5. REMOVE SPARK PLUG

    Click here

  6. REMOVE CAMSHAFT POSITION SENSOR


    1. A01SFD1

      Remove the bolt and camshaft position sensor.

  7. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY


    1. A01SFIX

      Remove the bolt and camshaft timing oil control valve assembly.

    2. Remove the O-ring from the camshaft timing oil control valve assembly.

  8. REMOVE CRANKSHAFT POSITION SENSOR


    1. A01SFA3

      Remove the bolt and crankshaft position sensor.

  9. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY


    1. A01SF9C

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

  10. REMOVE KNOCK CONTROL SENSOR


    1. A01SFBK

      Remove the bolt and knock control sensor.

  11. REMOVE ENGINE COOLANT TEMPERATURE SENSOR


    1. A01SFNH

      Remove the engine coolant temperature sensor and gasket.

  12. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A01SFDM

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

      Note

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

    2. A01SFGT

      Remove the 2 gaskets from the camshaft bearing cap.

  13. REMOVE CYLINDER HEAD COVER GASKET


    1. A01SFUF

      Remove the cylinder head cover gasket.

  14. REMOVE SPARK PLUG TUBE GASKET


    1. A01SFAM

      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. A01SFG4

      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.

      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 inserting the screwdriver in the joint area.

      Tech Tips

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

  15. REMOVE OIL FILTER CAP ASSEMBLY

    Click here

  16. REMOVE WATER INLET SUB-ASSEMBLY

    Tech Tips

    There are 2 installation types for the water inlet sub-assembly.

    Depending on the installation type, the number of bolts, nuts and stud bolts used will vary.


    1. Type A:


      1. A01SFL1

        Remove the bolt, 2 nuts, water inlet sub-assembly and gasket.

    2. Type B:


      1. A01SFSV

        Remove the 3 bolts, water inlet sub-assembly and gasket.

  17. REMOVE WATER INLET SUB-ASSEMBLY STUD BOLT

    Tech Tips


    • There are 2 installation types for the water inlet sub-assembly.

      Depending on the installation type, the number of bolts, nuts and stud bolts used will vary.

      This procedure is for type A.

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


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

  18. SET NO. 1 CYLINDER TO TDC/COMPRESSION

    Click here

  19. REMOVE CRANKSHAFT PULLEY

    Click here

  20. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY

    Click here

  21. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY

    Click here

  22. REMOVE TIMING CHAIN COVER OIL SEAL

    Click here

  23. REMOVE CHAIN TENSIONER SLIPPER

    Click here

  24. REMOVE NO. 1 CHAIN VIBRATION DAMPER

    Click here

  25. REMOVE NO. 2 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. A01SFH2

      Remove the No. 1 crankshaft position sensor plate.

  30. REMOVE CRANKSHAFT TIMING GEAR KEY


    1. A01SFO3C06
      *a Protective Tape

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

      Tech Tips

      Tape the screwdriver tip before use.

  31. INSPECT CAMSHAFT TIMING GEAR ASSEMBLY

    Click here

  32. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY

    Click here

  33. REMOVE CAMSHAFT TIMING SPROCKET

    Click here

  34. REMOVE CAMSHAFT BEARING CAP

    Click here

  35. REMOVE CAMSHAFT

    Click here

  36. REMOVE NO. 2 CAMSHAFT

    Click here

  37. REMOVE CAMSHAFT HOUSING STRAIGHT PIN

    Note

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

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


    1. A01SFGN

      Remove the 16 No. 1 valve rocker arms sub-assembly.

      Tech Tips

      Arrange the removed parts in the correct order.

  39. REMOVE VALVE LASH ADJUSTER ASSEMBLY


    1. A01SFLC

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

      Tech Tips

      Arrange the removed parts in the correct order.

  40. REMOVE VALVE STEM CAP


    1. A01SFG8

      Remove the 16 valve stem caps.

      Tech Tips

      Arrange the removed parts in the correct order.

  41. REMOVE OIL CONTROL VALVE FILTER


    1. A01SFGU

      Remove the oil control valve filter from the No. 1 camshaft bearing cap.

  42. REMOVE NO. 1 CAMSHAFT BEARING


    1. A01SFSA

      Remove the 2 No. 1 camshaft bearings.

  43. REMOVE NO. 2 CAMSHAFT BEARING


    1. A01SFHL

      Remove the 2 No. 2 camshaft bearings.

  44. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY

    Click here

  45. REMOVE CYLINDER HEAD SUB-ASSEMBLY

    Click here

  46. REMOVE CYLINDER HEAD GASKET

    Click here

  47. REMOVE VENTILATION VALVE SUB-ASSEMBLY


    1. A01SFVK

      Remove the ventilation valve sub-assembly.

  48. REMOVE OIL PAN DRAIN PLUG


    1. A01SFHF

      Remove the oil pan drain plug and gasket.

  49. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY

    Click here

  50. REMOVE OIL PUMP ASSEMBLY

    Click here

  51. REMOVE STIFFENING CRANKCASE ASSEMBLY


    1. A01SFEY

      Uniformly loosen and remove the 11 bolts.

    2. A01SF90C06
      *a Protective Tape

      Using a screwdriver, remove the stiffening crankcase assembly by prying between the stiffening crankcase assembly 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.

  52. REMOVE NO. 1 TAPER SCREW PLUG


    1. A01SFSO

      Remove the 2 No. 1 taper screw plugs.

  53. REMOVE STIFFENING CRANKCASE STUD BOLT

    Note

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


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

  54. REMOVE STIFFENING CRANKCASE RING PIN

    Note

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

  55. REMOVE REAR ENGINE OIL SEAL


    1. A01SFJ5

      Remove the rear engine oil seal from the cylinder block.