ENGINE UNIT DISASSEMBLY

PROCEDURE


  1. REMOVE NO. 1 FUEL PIPE SUB-ASSEMBLY (for High Pressure)

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  2. REMOVE FUEL DELIVERY PIPE (for Port Injection)

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  3. REMOVE FUEL INJECTOR ASSEMBLY (for Port Injection)

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  4. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY (for Direct Injection)

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  5. REMOVE FUEL INJECTOR SET (for Direct Injection)

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  6. REMOVE FUEL INJECTOR SEAL (for Direct Injection)

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  7. REMOVE FUEL PUMP ASSEMBLY (for High Pressure)

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  8. REMOVE VACUUM PUMP ASSEMBLY

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  9. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE

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  10. REMOVE NO. 3 EXHAUST MANIFOLD HEAT INSULATOR

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  11. REMOVE NO. 4 EXHAUST MANIFOLD HEAT INSULATOR

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  12. REMOVE NO. 1 WATER BY-PASS PIPE

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  13. REMOVE NO. 4 WATER BY-PASS PIPE


    1. B0057L7

      Slide the clamp and disconnect the No. 4 water by-pass hose from the oil cooler assembly.

    2. Remove the 2 nuts, bolt, No. 4 water by-pass pipe and gasket.

  14. REMOVE OIL PRESSURE SWITCHING VALVE ASSEMBLY

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  15. REMOVE WATER INLET HOUSING

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  16. REMOVE THERMOSTAT (for Cylinder Block)

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  17. REMOVE SPARK PLUG

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  18. REMOVE KNOCK SENSOR

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  19. REMOVE ENGINE COOLANT TEMPERATURE SENSOR

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  20. REMOVE OIL PRESSURE SENDER GAUGE ASSEMBLY

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  21. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY

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  22. REMOVE CRANKSHAFT POSITION SENSOR

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  23. REMOVE PCV VALVE SUB-ASSEMBLY

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  24. REMOVE NO. 1 PCV CASE


    1. B0057FS

      Remove the 6 bolts and 2 nuts.

    2. B005853

      Remove the No. 1 PCV case by prying between the No. 1 PCV 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 PCV case.

      Tech Tips

      Tape the screwdriver tip before use.

  25. REMOVE CRANKSHAFT PULLEY ASSEMBLY


    1. B0056YJC02
      *a Hold
      B0057RX 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. B005AEYC02
      *1 Crankshaft Pulley Set Bolt
      *a Hold
      B0057RX Turn

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

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

      Tech Tips

      Apply lubricant to the threads and end of SST.

  26. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY

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  27. REMOVE PCV HOSE (w/o Canister Pump Module)


    1. B0059AB

      Slide the clamp and remove the PCV hose from the cylinder head cover sub-assembly.

  28. REMOVE NO. 4 PCV HOSE (w/o Canister Pump Module)


    1. B005A70

      Slide the clamp and remove the No. 4 PCV hose from the cylinder head cover sub-assembly.

  29. REMOVE SPARK PLUG TUBE GASKET

    Note

    w/ Canister Pump Module:

    Be sure not to disconnect the PCV hose or the No. 4 PCV hose from the cylinder head cover sub-assembly.


    1. B005A8OC01
      *A w/o Canister Pump Module
      *B w/ Canister Pump Module
      *a Protective Tape

      Remove the spark plug tube gasket with a screwdriver.

      Note

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

      Tech Tips

      Tape the screwdriver tip before use.

  30. REMOVE TRANSVERSE ENGINE MOUNTING BRACKET

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  31. REMOVE CAMSHAFT TIMING OIL CONTROL SOLENOID ASSEMBLY

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  32. REMOVE TIMING CHAIN COVER ASSEMBLY

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

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  34. REMOVE TIMING CHAIN COVER PLATE


    1. B005BFI

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

  35. 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 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.

      B0059IVC02
      *1 Crankshaft Pulley Set Key - -
      *a Approximately 7° *b Approximately 32°
      *c Timing Mark - -

      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.

  36. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY


    1. B0056YSC02
      *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. B0059U9C02
      *a Pin

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

    3. B0059EG

      Remove the nut, bolt, No. 1 chain tensioner assembly and gasket.

  37. REMOVE TIMING CHAIN GUIDE


    1. B0058RF

      Remove the bolt and timing chain guide.

  38. REMOVE CHAIN TENSIONER SLIPPER


    1. B005B1K

      Remove the bolt and chain tensioner slipper.

  39. REMOVE CHAIN SUB-ASSEMBLY

  40. REMOVE NO. 1 CHAIN VIBRATION DAMPER


    1. B0058C7

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

  41. REMOVE CRANKSHAFT TIMING SPROCKET


    1. B0058UW

      Remove the crankshaft timing sprocket from the crankshaft.

  42. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY


    1. B005AKZC02
      *a Hold
      B0057RX Turn

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

      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.

  43. REMOVE CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY


    1. B0059AIC02
      *a Hold
      B0057RX Turn

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

      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.

  44. REMOVE OIL PIPE SUB-ASSEMBLY


    1. B0056XL

      Remove the bolt and oil pipe sub-assembly.

  45. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY


    1. B005AC7N04

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

    2. B005BAH

      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.

  46. REMOVE NO. 3 WATER BY-PASS PIPE


    1. B00580P

      Slide the clamp and disconnect the No. 6 water by-pass hose from the cylinder head sub-assembly.

    2. Remove the 3 bolts, No. 3 water by-pass pipe and gasket.

  47. REMOVE CAMSHAFT BEARING CAP


    1. B005AMXN04

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

    2. Remove the 4 camshaft bearing caps.

      Tech Tips

      Arrange the removed parts in the correct order.

  48. REMOVE OIL CONTROL VALVE FILTER


    1. B0059M4

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

  49. REMOVE CAMSHAFT


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

  50. REMOVE NO. 2 CAMSHAFT


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

  51. REMOVE NO. 1 CAMSHAFT BEARING


    1. B0059VR

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

  52. REMOVE NO. 2 CAMSHAFT BEARING


    1. B00598L

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

  53. 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.

  54. 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.

  55. 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.

  56. REMOVE CYLINDER HEAD SUB-ASSEMBLY

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  57. REMOVE CYLINDER HEAD GASKET

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  58. REMOVE CYLINDER BLOCK WATER JACKET SPACER


    1. B005AXK

      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.

  59. REMOVE OIL FILTER CAP ASSEMBLY

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  60. REMOVE OIL FILTER BRACKET CLIP


    1. B0057BV

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

  61. REMOVE OIL COOLER ASSEMBLY

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  62. REMOVE OIL PAN DRAIN PLUG


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

  63. REMOVE OIL PAN SUB-ASSEMBLY


    1. B0058NB

      Remove the 11 bolts and 2 nuts.

    2. B0058XY

      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.

  64. REMOVE ENGINE OIL LEVEL SENSOR

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  65. REMOVE OIL STRAINER SUB-ASSEMBLY


    1. B0059LW

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

  66. REMOVE NO. 1 OIL PAN BAFFLE PLATE


    1. B00590V

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

  67. INSPECT ENGINE BALANCER ASSEMBLY BACKLASH


    1. B005A2J

      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.

  68. REMOVE ENGINE BALANCER ASSEMBLY


    1. B0057C2

      Remove the 7 bolts and engine balancer assembly.

      Note

      Do not disassemble the engine balancer assembly.

  69. REMOVE ENGINE OIL TEMPERATURE SENSOR

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  70. REMOVE STIFFENING CRANKCASE ASSEMBLY


    1. B005A6U

      Remove the 8 bolts.

    2. B0058CF

      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.

  71. REMOVE REAR ENGINE OIL SEAL


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

  72. REMOVE STUD BOLT

    Note

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

  73. REMOVE RING PIN

    Note

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