ENGINE UNIT DISASSEMBLY

PROCEDURE


  1. REMOVE ENGINE COVER JOINT


    1. A01QVA4

      Remove the 3 engine cover joints.

  2. REMOVE SPARK PLUG

    Click here

  3. REMOVE OIL FILLER CAP SUB-ASSEMBLY


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

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

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

    Click here

  5. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Intake Side)

    Click here

  6. REMOVE CAMSHAFT POSITION SENSOR (for Exhaust Side)

    Click here

  7. REMOVE CAMSHAFT POSITION SENSOR (for Intake Side)

    Click here

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

    Click here

  9. REMOVE VENTILATION CASE SUB-ASSEMBLY


    1. A018IGQC02
      *a Bolt
      *b Nut

      Remove the 8 bolts and 2 nuts.

    2. A018J4Z

      Remove the ventilation case sub-assembly by prying between the ventilation case sub-assembly and cylinder block sub-assembly with a screwdriver.

      Note

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

      Tech Tips

      Tape the screwdriver tip before use.

  10. REMOVE SEPARATOR CASE


    1. A01QWBT

      Remove the 2 bolts, separator case and gasket.

  11. REMOVE NO. 1 WATER BY-PASS PIPE


    1. A018KYTC01
      *a Nut
      *b Bolt

      Remove the bolt, 2 nuts and No. 1 water by-pass pipe and gasket.

  12. REMOVE WATER INLET

    Click here

  13. REMOVE THERMOSTAT

    Click here

  14. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY


    1. A01QV9G

      Remove the bolt and V-ribbed belt tensioner assembly.

  15. REMOVE ENGINE WATER PUMP ASSEMBLY

    Click here

  16. REMOVE WATER INLET HOUSING


    1. A018KYNC02
      *a Bolt
      *b Nut

      Remove the 4 bolts, nut and water inlet housing and gasket.

  17. REMOVE CRANKSHAFT POSITION SENSOR

    Click here

  18. REMOVE CRANKSHAFT PULLEY


    1. A018HRUC07
      *a Hold
      *b Turn

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

      SST
      09213-54015
      09330-00021

      Tech Tips

      SST (crankshaft pulley holding tool) fixing bolt part No.: 91551-80650 (2 pcs)

    2. A018IU1C14
      *1 Crankshaft Pulley Bolt
      *a Hold
      *b Turn

      Using SST and the crankshaft pulley bolt, remove the crankshaft pulley and crankshaft pulley bolt.

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

      Tech Tips

      Apply lubricant to the threads and end of SST.

  19. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A018LHIC03
      *a Seal Washer

      Remove the 16 bolts, 3 seal washers and cylinder head cover sub-assembly and cylinder head cover gasket.

    2. A01QV39

      Remove the 3 camshaft bearing cap oil hole gaskets.

  20. REMOVE SPARK PLUG TUBE GASKET


    1. A018KPIC03
      *a Protective Tape

      Using a screwdriver, pry out the 4 spark plug tube gaskets.

      Note

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

      Tech Tips

      Tape the screwdriver tip before use.

  21. REMOVE ENGINE MOUNTING BRACKET RH

    Click here

  22. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY

    Click here

  23. REMOVE TIMING CHAIN COVER TIGHT PLUG


    1. A01QW12

      Using a 14 mm hexagon wrench, remove the timing chain cover tight plug and gasket.

  24. REMOVE TIMING CHAIN COVER PLATE


    1. A01QWOI

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

  25. REMOVE TIMING CHAIN COVER OIL SEAL

    Click here

  26. SET NO. 1 CYLINDER TO TDC/COMPRESSION

    Click here

  27. REMOVE TIMING CHAIN GUIDE

    Click here

  28. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY

    Click here

  29. REMOVE CHAIN TENSIONER SLIPPER

    Click here

  30. REMOVE CHAIN SUB-ASSEMBLY


    1. Remove the chain sub-assembly.

  31. REMOVE NO. 1 CHAIN VIBRATION DAMPER

    Click here

  32. REMOVE CRANKSHAFT TIMING SPROCKET


    1. A01QWTS

      Remove the crankshaft timing sprocket from the crankshaft.

  33. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY

    Click here

  34. REMOVE CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY

    Click here

  35. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY

    Click here

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

    Click here

  37. REMOVE VALVE LASH ADJUSTER ASSEMBLY

    Click here

  38. REMOVE VALVE STEM CAP

    Click here

  39. REMOVE CAMSHAFT BEARING CAP

    Click here

  40. REMOVE CAMSHAFT

    Click here

  41. REMOVE OIL CONTROL VALVE FILTER


    1. A0027GV

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

  42. REMOVE NO. 1 CAMSHAFT BEARING


    1. A018GZ1

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

  43. REMOVE NO. 2 CAMSHAFT BEARING


    1. A018L1G

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

  44. REMOVE CAMSHAFT HOUSING STUD BOLT

    Note

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


    1. Using an E8 "TORX" socket wrench, remove the stud bolt from the camshaft housing sub-assembly.

  45. REMOVE CAMSHAFT BEARING CAP SETTING RING PIN

    Note

    It is not necessary to remove the camshaft bearing cap setting ring pin unless it is being replaced.


    1. Remove the 10 camshaft bearing cap setting ring pins from the camshaft housing sub-assembly.

  46. REMOVE CAMSHAFT HOUSING STRAIGHT PIN

    Note

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


    1. Remove the 2 straight pins from the camshaft housing sub-assembly.

  47. REMOVE CYLINDER HEAD SUB-ASSEMBLY

    Click here

  48. REMOVE CYLINDER HEAD GASKET

    Click here

  49. REMOVE CYLINDER BLOCK WATER JACKET SPACER


    1. A01QVLM

      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.

  50. REMOVE OIL FILTER CAP ASSEMBLY

    Click here

  51. REMOVE OIL PAN DRAIN PLUG


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

  52. REMOVE OIL PAN SUB-ASSEMBLY


    1. A018HMYC13
      *a Nut

      Remove the 11 bolts and 2 nuts.

    2. A018HCV

      Insert the blade of an oil pan seal cutter between the oil pan sub-assembly and stiffening crankcase assembly, cut through the applied sealer and remove the oil pan sub-assembly.

      Note


      • Be careful not to damage the stiffening crankcase assembly contact surface of the oil pan sub-assembly.

      • Be careful not to damage the stiffening crankcase flange.

  53. REMOVE OIL STRAINER SUB-ASSEMBLY


    1. A018LNV

      Remove the 3 bolts, oil strainer sub-assembly and gasket.

  54. REMOVE NO. 1 OIL PAN BAFFLE PLATE


    1. A01QVKT

      Remove the 5 bolts and No. 1 oil pan baffle plate.

  55. INSPECT CRANKSHAFT BACKLASH


    1. A018H7U

      Using a dial indicator, measure the backlash of the crankshaft and balance shaft as shown in the illustration.

      Standard Backlash
      0.05 to 0.20 mm (0.00197 to 0.00787 in.)
      Maximum Backlash
      0.20 mm (0.00787 in.)

      If the backlash is more than the maximum, replace the engine balancer assembly.

  56. REMOVE ENGINE BALANCER ASSEMBLY


    1. A018JPH

      Remove the 7 bolts and engine balancer assembly.

      Note

      Do not disassemble the engine balancer assembly.

  57. INSPECT NO. 1 BALANCE SHAFT THRUST CLEARANCE

    Click here

  58. INSPECT NO. 2 BALANCE SHAFT THRUST CLEARANCE

    Click here

  59. REMOVE STIFFENING CRANKCASE ASSEMBLY


    1. A018M73

      Remove the 7 bolts.

    2. A018L03C10
      *a LH Side
      *b RH Side

      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.

  60. REMOVE STIFFENING CRANKCASE STUD BOLT

    Note

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


    1. Using an E5 and E8 "TORX" socket wrench, remove the 3 stud bolts from the stiffening crankcase assembly.

  61. REMOVE STIFFENING CRANKCASE RING PIN

    Note

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


    1. Remove the 2 ring pins from the stiffening crankcase assembly.

  62. REMOVE REAR ENGINE OIL SEAL


    1. A018I5M

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