ENGINE UNIT DISASSEMBLY

PROCEDURE


  1. REMOVE OIL FILLER CAP SUB-ASSEMBLY


    1. A01OEKY

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

  2. REMOVE OIL FILLER CAP GASKET


    1. A01OE10

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

  3. REMOVE ENGINE COVER JOINT


    1. A01OE8C

      Remove the 2 engine cover joints from the cylinder head cover sub-assembly.

  4. REMOVE SPARK PLUG

    Click here

  5. REMOVE CAMSHAFT POSITION SENSOR


    1. for Intake Side:

      Click here

    2. for Exhaust Side:

      Click here

  6. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY


    1. for Intake Side:

      Click here

    2. for Exhaust Side:

      Click here

  7. REMOVE CRANKSHAFT POSITION SENSOR

    Click here

  8. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY

    Click here

  9. REMOVE KNOCK CONTROL SENSOR

    Click here

  10. REMOVE ENGINE COOLANT TEMPERATURE SENSOR

    Click here

  11. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A01ODZV

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

    2. A01OE8Q

      Remove the 3 gaskets from the camshaft bearing cap.

      Note

      As 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.

  12. REMOVE CYLINDER HEAD COVER GASKET


    1. A01OEBC

      Remove the cylinder head cover gasket from the cylinder head cover sub-assembly.

  13. REMOVE SPARK PLUG TUBE GASKET


    1. A01OEQF

      Pry up the claws of the ventilation baffle plate.

      Note

      Do not deform the claws of the ventilation baffle plate more than necessary.

    2. A01OEJZ

      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.

  14. REMOVE OIL FILTER ELEMENT

    Click here

  15. SET NO. 1 CYLINDER TO TDC/COMPRESSION


    1. A01OF7LC04
      *a Timing Mark
      *b Timing Notch

      Turn the crankshaft until its timing notch and timing mark "0" of the timing chain cover sub-assembly are aligned.

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

      Tech Tips

      If the marks are not as shown, turn the crankshaft 1 complete revolution (360°) and align the marks as specified above.

  16. REMOVE CRANKSHAFT PULLEY

    Click here

  17. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY


    1. A01OEHA

      Remove the 2 nuts, bracket, No. 1 chain tensioner assembly and gasket.

      Note

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

  18. REMOVE TRANSVERSE ENGINE MOUNTING BRACKET STUD BOLT

    Tech Tips

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


    1. A01OE69

      Remove the engine mounting bracket stud bolt from the engine mounting bracket RH.

  19. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY

    Click here

  20. REMOVE TIMING CHAIN COVER OIL SEAL

    Click here

  21. REMOVE WATER INLET HOUSING


    1. A01OEEK

      Remove the 3 bolts, water inlet housing and gasket.

  22. REMOVE NO. 1 GENERATOR BRACKET


    1. A01OEEU

      Remove the 4 bolts and No. 1 generator bracket.

  23. REMOVE CHAIN TENSIONER SLIPPER


    1. A01OE5K

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

  24. REMOVE NO. 1 CHAIN VIBRATION DAMPER


    1. A01OF5G

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

  25. REMOVE CHAIN SUB-ASSEMBLY


    1. A01ODYZ

      Hold the hexagonal portion of the camshaft with a wrench and turn the camshaft timing gear assembly counterclockwise to loosen the chain sub-assembly between the camshaft timing exhaust gear assembly and camshaft timing gear assembly.

    2. With the chain sub-assembly loosened, release the chain sub-assembly from the camshaft timing gear assembly and place it on the camshaft timing gear assembly.

      Tech Tips

      Be sure to release the chain sub-assembly from the sprocket completely.

    3. Turn the camshaft clockwise to return it to the original position and remove the chain sub-assembly.

  26. REMOVE CRANKSHAFT TIMING SPROCKET

    Click here

  27. REMOVE NO. 2 CHAIN SUB-ASSEMBLY

    Click here

  28. REMOVE NO. 1 CRANKSHAFT POSITION SENSOR PLATE


    1. A01OEYN

      Remove the No. 1 crankshaft position sensor plate.

  29. REMOVE CRANKSHAFT TIMING GEAR KEY


    1. A01OEGUC19
      *a Protective Tape

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

      Tech Tips

      Tape the screwdriver tip before use.

  30. INSPECT CAMSHAFT TIMING GEAR ASSEMBLY

    Click here

  31. INSPECT CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY

    Click here

  32. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY

    Click here

  33. REMOVE CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY

    Click here

  34. REMOVE VALVE ROCKER ARM LOST MOTION DAMPER SUB-ASSEMBLY

    Click here

  35. INSTALL VALVE ROCKER ARM LOST MOTION DAMPER SUB-ASSEMBLY

    Click here

  36. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY

    Click here

  37. REMOVE CONTINUOUSLY VARIABLE VALVE LIFT CONTROLLER ASSEMBLY


    1. A01OEHG

      Using a screwdriver, slide the valve lift control actuator connector clip from the valve lift control actuator connector.

      Note

      Slide only the upper part of the valve lift control actuator connector clip, as the straight pin will fall out from the bottom if the valve lift control actuator connector clip is completely removed.

    2. A01OE6H

      Using 2 screwdrivers, lightly pry the valve lift control actuator connector to make a space between the continuously variable valve lift controller assembly and camshaft housing sub-assembly.

      Note


      • Do not forcefully pry the valve lift control actuator connector.

      • Do not damage the camshaft housing sub-assembly and camshaft bearing cap.

    3. A01OEDF

      Using a magnet hand, remove the straight pin from the valve lift control actuator connector.

      Tech Tips

      The straight pin can be removed by utilizing the space between the continuously variable valve lift controller assembly and camshaft housing sub-assembly to move the continuously variable valve lift controller assembly so that there is no load on the straight pin.

    4. A01OEDGC01
      *1 Continuously Variable Valve Lift Controller Assembly
      *2 O-Ring

      Remove the bolt and the continuously variable valve lift controller assembly from the camshaft housing sub-assembly.

    5. Remove the O-ring from the continuously variable valve lift controller assembly.

      Note

      The O-ring may remain on the camshaft housing side. Be sure to always remove it.

    6. A01OF5K

      Remove the valve lift control actuator connector from the valve rocker shaft assembly.

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


    1. A01OEUV

      Remove the 16 No. 1 valve rocker arm sub-assemblies.

      Tech Tips

      Arrange the removed parts in the correct order.

  39. REMOVE VALVE LASH ADJUSTER ASSEMBLY


    1. A01OEF0

      Remove the 16 valve lash adjuster assemblies.

      Tech Tips

      Arrange the removed parts in the correct order.

  40. REMOVE VALVE STEM CAP


    1. A01OEYT

      Remove the 16 valve stem caps.

      Tech Tips

      Arrange the removed parts in the correct order.

  41. REMOVE CYLINDER HEAD SUB-ASSEMBLY

    Click here

  42. REMOVE CAMSHAFT HOUSING STRAIGHT PIN

    Note

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

  43. REMOVE CYLINDER HEAD GASKET

    Click here

  44. REMOVE PCV VALVE SUB-ASSEMBLY

    Click here

  45. REMOVE OIL PAN DRAIN PLUG


    1. A01OEWO

      Remove the oil pan drain plug and gasket.

  46. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY

    Click here

  47. REMOVE OIL PUMP ASSEMBLY

    Click here

  48. REMOVE REAR ENGINE OIL SEAL

    Click here

  49. REMOVE STIFFENING CRANKCASE ASSEMBLY


    1. A01OEEY

      Uniformly loosen and remove the 11 bolts.

    2. A01OF6NC17
      *a Protective Tape

      Using a screwdriver, remove the stiffening crankcase assembly by prying between the stiffening crankcase assembly and cylinder block sub-assembly.

      Note

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

      Tech Tips

      Tape the screwdriver tip before use.

  50. REMOVE NO. 1 TAPER SCREW PLUG


    1. A01OEE5

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

  51. REMOVE STUD BOLT

    Note

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

  52. REMOVE STIFFENING CRANKCASE RING PIN

    Note

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