ENGINE UNIT DISASSEMBLY

PROCEDURE


  1. REMOVE SPARK PLUG

    Click here

  2. REMOVE CAMSHAFT POSITION SENSOR (for Exhaust Side)

    Click here

  3. REMOVE CAMSHAFT POSITION SENSOR (for Intake Side)

    Click here

  4. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Exhaust Side)

    Click here

  5. REMOVE KNOCK CONTROL SENSOR

    Click here

  6. REMOVE OIL PRESSURE SENDER GAUGE ASSEMBLY

    Click here

  7. REMOVE CRANK POSITION SENSOR

    Click here

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

    Click here

  9. REMOVE NO. 1 VENTILATION CASE


    1. A01MYYZC01
      B003WAF Bolt
      B003U82 Nut

      Remove the 6 bolts and 2 nuts.

    2. A01MWRB

      Remove the No. 1 ventilation case by prying between the No. 1 ventilation case and cylinder block sub-assembly with a screwdriver.

      Note


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

      • Do not reuse the No. 1 ventilation case.

      Tech Tips

      Tape the screwdriver tip before use.

  10. REMOVE CRANKSHAFT PULLEY ASSEMBLY


    1. A01MZ7CC01
      *a Hold
      B003WAF Turn

      Using SST, hold the crankshaft pulley assembly and loosen the crankshaft pulley set bolt until 2 or 3 threads are screwed into the crankshaft.

      SST
      09213-54015
      09330-00021

      Tech Tips

      Part number of installation bolt for SST (crankshaft pulley holding tool): 91551-80650 (quantity: 2)

    2. A01MX39C01
      *1 Crankshaft Pulley Set Bolt
      *a Hold
      B003WAF Turn

      Using SST and the crankshaft pulley set bolt, remove the crankshaft pulley assembly from the crankshaft.

      SST
      09950-50013   ( 09951-05010, 09952-05010, 09953-05020, 09954-05011, 09957-04010 )

      Tech Tips

      Apply lubricant to the threads and end of SST.

  11. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY

    Click here

  12. REMOVE CYLINDER HEAD COVER GASKET

    Click here

  13. REMOVE CAMSHAFT BEARING CAP OIL HOLE GASKET

    Click here

  14. REMOVE SPARK PLUG TUBE GASKET


    1. A01MVHJC03
      *a Protective Tape

      Using a screwdriver, remove the 4 spark plug tube gaskets from the cylinder head cover sub-assembly.

      Note

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

      Tech Tips

      Tape the screwdriver tip before use.

  15. REMOVE CAM TIMING OIL CONTROL SOLENOID ASSEMBLY

    Click here

  16. REMOVE E.F.I. ENGINE COOLANT TEMPERATURE SENSOR

    Click here

  17. REMOVE WATER OUTLET SUB-ASSEMBLY


    1. A01MVKWC01
      *1 No. 6 Water By-pass Hose
      B003WAF Bolt
      B003U82 Nut

      Slide the clip and disconnect the No. 6 water by-pass hose from the water outlet sub-assembly.

    2. Remove the 2 bolts, nut and water outlet sub-assembly from the timing chain cover assembly.

    3. Remove the O-ring from the timing chain cover assembly.

  18. REMOVE TIMING CHAIN COVER ASSEMBLY

    Click here

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

    Click here

  20. REMOVE TIMING CHAIN COVER PLATE


    1. A001KPV

      Remove the 4 bolts, timing chain cover plate and gasket from the timing chain cover assembly.

  21. 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 (groove) on the camshaft timing gear assembly and camshaft timing exhaust gear assembly and the crankshaft pulley set key of the crankshaft timing sprocket are as shown in the illustration.

      A01MVR7C01
      *1 Crankshaft Pulley Set Key - -
      *a Approximately 7° *b Approximately 32°
      *c Timing Mark (Groove) - -

      Tech Tips

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

    3. Remove the crankshaft pulley set bolt.

  22. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY


    1. A01MWNUC01
      *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 No. 1 chain tensioner assembly.

    2. A01MWZIC01
      *a Pin

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

    3. A01MYZOC01
      B003WAF Bolt
      B003U82 Nut

      Remove the nut, bolt, No. 1 chain tensioner assembly and gasket from the cylinder block sub-assembly.

  23. REMOVE TIMING CHAIN GUIDE


    1. A001IX1

      Remove the bolt and timing chain guide from the No. 1 camshaft bearing cap.

  24. REMOVE CHAIN TENSIONER SLIPPER


    1. A001K68

      Remove the bolt and chain tensioner slipper from the cylinder head sub-assembly.

  25. REMOVE CHAIN SUB-ASSEMBLY


    1. Remove the chain sub-assembly.

  26. REMOVE NO. 1 CHAIN VIBRATION DAMPER


    1. A001JZN

      Remove the 2 bolts and No. 1 chain vibration damper from the cylinder head sub-assembly and cylinder block sub-assembly.

  27. REMOVE CRANKSHAFT TIMING GEAR OR SPROCKET


    1. A01MV5J

      Remove the crankshaft timing gear or sprocket from the crankshaft.

  28. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY


    1. A01MXK8C01
      *a Hold
      B003WAF Turn

      Hold the hexagonal portion of the camshaft with a wrench and remove the camshaft timing gear bolt and camshaft timing gear assembly from the camshaft.

      Note


      • Be careful not to damage the camshaft housing sub-assembly or spark plug tube with the wrench.

      • Do not disassemble the camshaft timing gear assembly.

  29. REMOVE CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY


    1. A01MZ39C01
      *a Hold
      B003WAF Turn

      Hold the hexagonal portion of the No. 2 camshaft with a wrench and remove the bolt and camshaft timing exhaust gear assembly from the No. 2 camshaft.

      Note


      • Be careful not to damage the camshaft housing sub-assembly or spark plug tube with the wrench.

      • Do not disassemble the camshaft timing exhaust gear assembly.

  30. REMOVE OIL PIPE SUB-ASSEMBLY


    1. A001I3G

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

  31. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY


    1. A01MXESN04

      Uniformly loosen and remove the 22 bearing cap bolts in the sequence shown in the illustration.

    2. A01MXLB

      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.

  32. REMOVE NO. 3 WATER BY-PASS PIPE


    1. A001J3W

      Remove the 3 bolts, No. 3 water by-pass pipe and gasket from the cylinder head sub-assembly.

  33. REMOVE CAMSHAFT BEARING CAP


    1. A01MUOSN04

      Remove the 11 bearing cap bolts in the sequence shown in the illustration.

    2. Remove the No. 1, No. 2, No. 3 and No. 4 camshaft bearing caps from the camshaft housing sub-assembly.

      Tech Tips

      Arrange the removed parts in the correct order.

  34. REMOVE OIL CONTROL VALVE FILTER


    1. A001JJK

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

  35. REMOVE CAMSHAFT


    1. Remove the camshaft from the camshaft housing sub-assembly.

  36. REMOVE NO. 2 CAMSHAFT


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

  37. REMOVE NO. 1 CAMSHAFT BEARING


    1. A01MUSR

      Remove the No. 1 camshaft bearing from the No. 1 camshaft bearing cap.

  38. REMOVE NO. 2 CAMSHAFT BEARING


    1. A01MUUT

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

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


    1. Remove the 16 No. 1 valve rocker arm sub-assemblies from the cylinder head sub-assembly.

      Tech Tips

      Arrange the removed parts in the correct order.

  40. REMOVE VALVE LASH ADJUSTER ASSEMBLY


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

      Tech Tips

      Arrange the removed parts in the correct order.

  41. REMOVE VALVE STEM CAP


    1. Remove the 16 valve stem caps from the cylinder head sub-assembly.

      Tech Tips

      Arrange the removed parts in the correct order.

  42. REMOVE CYLINDER HEAD SUB-ASSEMBLY

    Click here

  43. REMOVE CYLINDER HEAD GASKET

    Click here

  44. REMOVE CYLINDER BLOCK WATER JACKET SPACER


    1. A01MUT7

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

      Note

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

  45. REMOVE OIL FILTER CAP ASSEMBLY

    Click here

  46. REMOVE OIL FILTER BRACKET CLIP


    1. A01MUZN

      Remove the oil filter bracket clip from the stiffening crankcase assembly.

  47. REMOVE OIL COOLER ASSEMBLY

    Click here

  48. REMOVE ENGINE OIL LEVEL SENSOR

    Click here

  49. REMOVE OIL PAN DRAIN PLUG


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

  50. REMOVE OIL PAN SUB-ASSEMBLY


    1. A01MX51C01
      B003WAF Bolt
      B003U82 Nut

      Remove the 11 bolts and 2 nuts.

    2. A001KOS

      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 surfaces of the stiffening crankcase assembly and oil pan sub-assembly.

      • Be careful not to damage the stiffening crankcase assembly flange.

  51. REMOVE OIL STRAINER SUB-ASSEMBLY


    1. A01MWL5

      Remove the 3 bolts, oil strainer sub-assembly and gasket from the stiffening crankcase assembly and engine balancer assembly.

  52. REMOVE NO. 1 OIL PAN BAFFLE PLATE


    1. A001KKS

      Remove the 4 bolts and No. 1 oil pan baffle plate from the engine balancer assembly.

  53. REMOVE ENGINE BALANCER ASSEMBLY


    1. A01MUR6

      Remove the 5 bolts and engine balancer assembly from the stiffening crankcase assembly.

      Note

      Do not disassemble the engine balancer assembly.

  54. REMOVE TEMPERATURE SENSOR

    Click here

  55. REMOVE STIFFENING CRANKCASE ASSEMBLY


    1. A01MZA1

      Remove the 8 bolts.

    2. A01MYUF

      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

      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.

  56. REMOVE REAR ENGINE OIL SEAL


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

  57. REMOVE STUD BOLT

    Note

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

  58. REMOVE RING PIN

    Note

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