ENGINE UNIT DISASSEMBLY

PROCEDURE


  1. REMOVE OIL FILLER CAP SUB-ASSEMBLY


    1. B004POY

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

  2. REMOVE OIL FILLER CAP GASKET


    1. B004OMJC01
      *a Protective Tape

      Using a screwdriver with its tip wrapped with protective tape, remove the oil filler cap gasket from the oil filler cap sub-assembly.

  3. REMOVE SPARK PLUG

    Click here

  4. REMOVE CAMSHAFT POSITION SENSOR

    Click here

  5. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY

    Click here

  6. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY


    1. B004QQQ

      Remove the 16 bolts and cylinder head cover sub-assembly from the camshaft housing sub-assembly.

    2. B004PZ5

      Remove the 2 gaskets from the camshaft bearing cap.

      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.

  7. REMOVE CYLINDER HEAD COVER GASKET


    1. B004PL1

      Remove the 3 cylinder head cover gaskets from the cylinder head cover sub-assembly.

  8. REMOVE SPARK PLUG TUBE GASKET


    1. B004Q4PC01
      *a Protective Tape

      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.

  9. SET NO. 1 CYLINDER TO TDC (COMPRESSION)


    1. B004QULC01
      *a Timing Mark
      *b Timing Notch
      *c Timing Mark (Rectangle)
      *d Mark (Circle)

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

      Tech Tips

      There are 3 marks on the camshaft timing sprocket. Make sure that the timing mark (rectangle) is at the top.

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

      Tech Tips

      If not, turn the crankshaft 1 complete revolution (360°) and align the timing marks as shown in the illustration.

  10. REMOVE CRANKSHAFT PULLEY

    Click here

  11. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY


    1. B004R0P

      Remove the 2 nuts, bracket, No. 1 chain tensioner assembly and gasket from the timing chain cover sub-assembly.

      Note

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

  12. REMOVE CRANKSHAFT POSITION SENSOR

    Click here

  13. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY

    Click here

  14. REMOVE NO. 1 TAPER SCREW PLUG


    1. Type A:


      1. B004PVX

        Remove the 2 No. 1 taper screw plugs from the cylinder block sub-assembly.

    2. Type B:


      1. B004OOY

        Remove the No. 1 taper screw plugs from the cylinder block sub-assembly.

  15. REMOVE KNOCK CONTROL SENSOR

    Click here

  16. REMOVE OIL FILTER CAP ASSEMBLY

    Click here

  17. REMOVE OIL FILTER BRACKET CLIP


    1. B004QHJ

      Remove the oil filter bracket clip from the oil filter bracket.

  18. REMOVE WATER INLET WITH THERMOSTAT SUB-ASSEMBLY

    Click here

  19. REMOVE TIMING CHAIN COVER OIL SEAL

    Click here

  20. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY


    1. B004PM7

      Remove the 3 bolts and engine mounting bracket RH from the timing chain cover sub-assembly.

    2. B004OQF

      Remove the 4 bolts and oil filter bracket from the timing chain cover sub-assembly.

    3. B004P6Q

      Remove the 2 oil filter bracket O-rings from the timing chain cover sub-assembly.

    4. B004OZ6C06
      *1 Seal Washer

      Remove the 18 bolts and seal washer from the timing chain cover sub-assembly.

    5. B004R0EC01
      *a Protective Tape

      Remove the timing chain cover sub-assembly by prying between the timing chain cover sub-assembly and cylinder head sub-assembly, camshaft housing sub-assembly, cylinder block sub-assembly and stiffening crankcase assembly with a screwdriver with its tip wrapped with protective tape.

      Note

      Be careful not to damage the contact surfaces of the cylinder head sub-assembly, camshaft housing sub-assembly, cylinder block sub-assembly, stiffening crankcase assembly and timing chain cover sub-assembly.

    6. B004PNE

      Remove the 3 O-rings from the cylinder head sub-assembly and cylinder block sub-assembly.

    7. B004PZC

      Remove the 3 bolts and engine water pump assembly from the timing chain cover sub-assembly.

    8. B004OP3

      Remove the gasket from the engine water pump assembly.

  21. REMOVE OIL FILTER BRACKET WITH HEAD STRAIGHT SCREW PLUG


    1. B004P86

      Using a 10 mm hexagon socket wrench, remove the 2 oil filter bracket with head straight screw plugs and 2 gaskets from the oil filter bracket.

  22. REMOVE CHAIN TENSIONER SLIPPER


    1. B004OHA

      Remove the chain tensioner slipper from the cylinder block sub-assembly.

  23. REMOVE NO. 1 CHAIN VIBRATION DAMPER


    1. B004P4G

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

  24. REMOVE NO. 2 CHAIN VIBRATION DAMPER


    1. B004PHH

      Remove the 2 bolts and No. 2 chain vibration damper from the camshaft housing sub-assembly.

  25. REMOVE CHAIN SUB-ASSEMBLY

    Click here

  26. REMOVE CRANKSHAFT TIMING SPROCKET


    1. B004PFX

      Remove the crankshaft timing sprocket from the crankshaft.

  27. REMOVE NO. 2 CHAIN SUB-ASSEMBLY


    1. Temporarily install the crankshaft pulley with the crankshaft pulley set bolt.

    2. B004PL9N01

      Using SST, hold the crankshaft pulley. Then remove the oil pump drive shaft gear nut.

      SST
      09213-58014   ( 91551-80840 )
      09330-00021

    3. Remove SST, the crankshaft pulley set bolt and crankshaft pulley.

    4. B004OM5C01
      *1 Chain Tensioner Plate
      *2 Chain Damper Spring

      Remove the bolt, chain tensioner plate and chain damper spring.

    5. B004P01C01
      *1 No. 2 Chain Sub-assembly
      *2 Oil Pump Drive Gear
      *3 Oil Pump Drive Shaft Gear

      Remove the oil pump drive gear, oil pump drive shaft gear and No. 2 chain sub-assembly.

  28. REMOVE NO. 1 CRANKSHAFT POSITION SENSOR PLATE


    1. B004PHF

      Remove the No. 1 crankshaft position sensor plate from the crankshaft.

  29. REMOVE CRANKSHAFT TIMING GEAR KEY


    1. B004PD3C01
      *a Protective Tape

      Using a screwdriver with its tip wrapped with protective tape, remove the 2 crankshaft timing gear keys from the crankshaft.

  30. INSPECT CAMSHAFT TIMING GEAR ASSEMBLY


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

    2. B004QLNC01
      *a Adhesive Tape Sealing Area
      *b Prick a hole
      *c Adhesive Tape

      After cleaning the VVT oil hole in 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.

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

    4. B004OM8

      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 the adhesive tape.

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

    5. Forcibly turn the camshaft timing gear assembly in the advance direction (counterclockwise).

      Tech Tips

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

    6. B004QJ6

      Turn the camshaft timing gear assembly within its movable range (30 to 32°) 2 or 3 times without turning it to the most retarded position. Make sure that the camshaft timing gear assembly turns smoothly.

      Note


      • Do not lock the camshaft timing gear assembly.

      • If camshaft timing gear assembly is locked, release the lock pin again.

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

  31. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY


    1. B004QUT

      Using a wrench to hold the hexagonal portion of the camshaft, remove the bolt and camshaft timing gear assembly.

      Note


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

      • Be sure not to remove the other 4 bolts.

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

      B004Q1TC01
      *a Do Not Remove

  32. REMOVE CAMSHAFT TIMING SPROCKET


    1. B004Q0W

      Using a wrench to hold the hexagonal portion of the No. 2 camshaft, remove the bolt and camshaft timing sprocket.

  33. REMOVE CAMSHAFT BEARING CAP


    1. B004PS2N01

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

    2. B004QNHN01

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

      Note

      Make sure that the camshaft and No. 2 camshaft remain level while uniformly loosening the bolts.

    3. Remove the 5 camshaft bearing caps.

      Tech Tips

      Arrange the removed parts in such a way that they can be reinstalled to their original locations.

  34. REMOVE CAMSHAFT


    1. B004PF4

      Remove the camshaft from the camshaft housing sub-assembly.

  35. REMOVE NO. 2 CAMSHAFT

    Click here

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


    1. B004OFM

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

      Tech Tips

      Arrange the removed parts in such a way that they can be reinstalled to their original locations.

  37. REMOVE VALVE LASH ADJUSTER ASSEMBLY


    1. B004QS3

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

      Tech Tips

      Arrange the removed parts in such a way that they can be reinstalled to their original locations.

  38. REMOVE VALVE STEM CAP


    1. B004P0L

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

      Tech Tips

      Arrange the removed parts in such a way that they can be reinstalled to their original locations.

  39. REMOVE OIL CONTROL VALVE FILTER


    1. B004P0G

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

  40. REMOVE NO. 1 CAMSHAFT BEARING


    1. B004PE0

      Remove the 2 No. 1 camshaft bearings from the No. 1 camshaft bearing cap.

  41. REMOVE NO. 2 CAMSHAFT BEARING


    1. B004QVX

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

  42. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY


    1. B004QDIN01

      Remove the 2 bolts from the camshaft housing sub-assembly.

    2. B004OH4C01
      *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 with its tip wrapped with protective tape.

      Note

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

  43. REMOVE CYLINDER HEAD SUB-ASSEMBLY


    1. B004OOMN01

      Using a 10 mm bi-hexagon socket wrench, uniformly loosen and remove the 10 cylinder head set bolts and 10 cylinder head set plate washers in several steps in the order shown in the illustration.

      Note


      • Do not drop the cylinder head set plate washers into the cylinder head sub-assembly.

      • Removing the cylinder head set bolts in the incorrect order may cause warpage or cracking of the cylinder head sub-assembly.

      Tech Tips

      Arrange the removed parts in such a way that they can be reinstalled to their original locations.

    2. Remove the cylinder head sub-assembly from the cylinder block sub-assembly.

  44. REMOVE CYLINDER HEAD GASKET

    Click here

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

    Click here

  46. REMOVE OIL PAN DRAIN PLUG


    1. B004PU5

      Remove the oil pan drain plug and gasket from the No. 2 oil pan sub-assembly.

  47. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY


    1. B004Q60C01
      *a Nut

      Remove the 10 bolts and 2 nuts from the No. 2 oil pan sub-assembly.

    2. B004OG0

      Insert the blade of an oil pan seal cutter between the stiffening crankcase assembly and No. 2 oil pan sub-assembly. Cut through the applied sealer and remove the No. 2 oil pan sub-assembly.

      Note


      • Be careful not to damage the surface of the No. 2 oil pan sub-assembly which contacts the stiffening crankcase assembly.

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

  48. REMOVE ENGINE OIL LEVEL SENSOR

    Click here

  49. REMOVE OIL PUMP ASSEMBLY

    Click here

  50. REMOVE STIFFENING CRANKCASE ASSEMBLY


    1. B004PHG

      Uniformly loosen and remove the 11 bolts from the stiffening crankcase assembly.

    2. B004PA1C01
      *a Protective Tape

      Remove the stiffening crankcase assembly by prying between the stiffening crankcase assembly and cylinder block sub-assembly with a screwdriver with its tip wrapped with protective tape.

      Note

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

  51. REMOVE REAR ENGINE OIL SEAL


    1. B004Q0H

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

      Note

      Be careful not to damage the crankshaft.

  52. REMOVE STUD BOLT

    Note

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

  53. REMOVE RING PIN

    Note

    It is not necessary to remove ring pins unless they are being replaced.