ENGINE UNIT DISASSEMBLY

PROCEDURE


  1. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY

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  2. REMOVE ENGINE COOLANT TEMPERATURE SENSOR

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  3. REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY


    1. Remove the cylinder block water drain cock sub-assembly.

    2. Remove the cylinder block water drain cock plug from the cylinder block water drain cock sub-assembly.

  4. REMOVE VVT SENSOR (for Bank 1)

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  5. REMOVE VVT SENSOR (for Bank 2)

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  6. REMOVE CRANKSHAFT POSITION SENSOR

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  7. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Bank 1)

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  8. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Bank 2)

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  9. REMOVE OIL CONTROL VALVE FILTER


    1. A01SE8AC02
      *A for Bank 1
      *B for Bank 2

      Remove the 2 unions, 2 oil control valve filters and 2 gaskets.

  10. REMOVE OIL FILTER SUB-ASSEMBLY

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  11. REMOVE OIL COOLER ASSEMBLY

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  12. REMOVE OIL FILTER BRACKET SUB-ASSEMBLY

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  13. REMOVE WATER INLET ASSEMBLY

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  14. REMOVE REAR WATER BY-PASS JOINT


    1. A01L8KH

      Remove the 2 bolts, 4 nuts, rear water by-pass joint and 2 gaskets.

    2. Remove the O-ring from the No. 1 water outlet pipe.

  15. REMOVE OIL FILLER CAP SUB-ASSEMBLY


    1. Remove the oil filler cap sub-assembly.

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

  16. REMOVE OIL FILLER CAP HOUSING


    1. Remove the 2 nuts, oil filler cap housing and gasket.

  17. REMOVE SPARK PLUG

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  18. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY

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  19. REMOVE PCV VALVE SUB-ASSEMBLY

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  20. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH

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  21. SET NO. 1 CYLINDER TO TDC/COMPRESSION

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  22. REMOVE CRANKSHAFT PULLEY

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  23. REMOVE OIL PAN DRAIN PLUG


    1. Remove the oil pan drain plug and gasket.

  24. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY

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  25. REMOVE OIL STRAINER SUB-ASSEMBLY

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  26. REMOVE OIL PAN SUB-ASSEMBLY

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  27. REMOVE ENGINE REAR OIL SEAL RETAINER


    1. A01SA8OC01
      *a Pry
      *b Protective Tape

      Remove the 5 bolts and 2 nuts.

    2. Using a screwdriver, remove the engine rear oil seal retainer by prying between the engine rear oil seal retainer and crankshaft bearing cap.

      Tech Tips

      Tape the screwdriver tip before use.

  28. REMOVE REAR CRANKSHAFT OIL SEAL


    1. A01LCHD

      Using a screwdriver and hammer, tap out the rear crankshaft oil seal.

      Note

      Be careful not to damage the engine rear oil seal retainer.

  29. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY

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  30. REMOVE ENGINE WATER PUMP ASSEMBLY


    1. A01L8IC

      Remove the 8 bolts, engine water pump assembly and gasket.

  31. REMOVE TIMING CHAIN COVER PLATE

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  32. REMOVE FRONT CRANKSHAFT OIL SEAL

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  33. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY

    Note


    • Never rotate the crankshaft with the No. 1 chain tensioner assembly removed.

    • When rotating the camshaft with the timing chain removed, rotate the crankshaft counterclockwise 40° from TDC first.


    1. A01SDH0C01
      *a Push
      *b Stopper Plate

      While turning the stopper plate of the No. 1 chain tensioner assembly clockwise, push in the plunger of the No. 1 chain tensioner assembly as shown in the illustration.

    2. While turning the stopper plate of the No. 1 chain tensioner assembly counterclockwise, insert a bar with a diameter of 3.5 mm (0.138 in.) into the holes in the stopper plate and No. 1 chain tensioner assembly to fix the stopper plate in place.

    3. Remove the 2 bolts and No. 1 chain tensioner assembly.

  34. REMOVE CHAIN TENSIONER SLIPPER

  35. REMOVE IDLE SPROCKET ASSEMBLY


    1. A01LDQ5

      Using a 10 mm hexagon wrench, remove the No. 2 idle gear shaft, idle sprocket assembly and No. 1 idle gear shaft.

  36. REMOVE NO. 2 CHAIN VIBRATION DAMPER


    1. A01LCEY

      Remove the 2 No. 2 chain vibration dampers.

  37. REMOVE CHAIN SUB-ASSEMBLY

  38. REMOVE CRANKSHAFT TIMING SPROCKET


    1. A01LFBY

      Remove the crankshaft timing sprocket.

  39. REMOVE NO. 1 CHAIN VIBRATION DAMPER


    1. A01LCUQ

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

  40. REMOVE CAMSHAFT TIMING GEARS AND NO. 2 CHAIN SUB-ASSEMBLY (for Bank 1)


    1. A01W97DC01
      *a Raise

      While raising the No. 2 chain tensioner assembly, insert a pin with a diameter of 1.0 mm (0.0394 in.) into the hole to fix the No. 2 chain tensioner assembly in place.

    2. A01LBAO

      Hold the hexagonal portion of the No. 2 camshaft with a wrench and remove the 2 bolts, camshaft timing gear sub-assembly, camshaft timing sprocket and No. 2 chain sub-assembly.

      Note


      • Do not damage the surrounding parts.

      • Do not disassemble the camshaft timing gear sub-assembly.

  41. REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY


    1. A01LERV

      Remove the bolt and No. 2 chain tensioner assembly.

  42. REMOVE CAMSHAFT TIMING GEARS AND NO. 2 CHAIN SUB-ASSEMBLY (for Bank 2)


    1. A01WAYTC01
      *a Push

      While raising the No. 3 chain tensioner assembly, insert a pin with a diameter of 1.0 mm (0.0394 in.) into the hole to fix the No. 3 chain tensioner assembly in place.

    2. A01LG1M

      Hold the hexagonal portion of the No. 4 camshaft sub-assembly with a wrench and remove the 2 bolts, camshaft timing gear sub-assembly, camshaft timing sprocket and No. 2 chain sub-assembly.

      Note


      • Do not damage the surrounding parts.

      • Do not disassemble the camshaft timing gear sub-assembly.

  43. REMOVE NO. 3 CHAIN TENSIONER ASSEMBLY


    1. A01L91Q

      Remove the bolt and No. 3 chain tensioner assembly.

  44. REMOVE CAMSHAFT BEARING CAP (for Bank 1)

    Note

    As the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being removed. If the camshaft is not kept level, the portion of the cylinder head which receives the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, make sure the following steps are carried out.


    1. A01LFH3

      Rotate the camshaft and No. 2 camshaft counterclockwise and set the camshaft and No. 2 camshaft as shown in the illustration.

    2. A01SE17N01

      Uniformly loosen the 16 bolts in the sequence shown in the illustration and remove the bolts and 8 camshaft bearing caps.

  45. REMOVE CAMSHAFT

  46. REMOVE NO. 2 CAMSHAFT

  47. REMOVE NO. 1 CAMSHAFT BEARING

    A01LD0Y

  48. REMOVE NO. 2 CAMSHAFT BEARING

    A01L8V9

  49. REMOVE CAMSHAFT BEARING CAP (for Bank 2)


    1. A01SE8KN01

      Uniformly loosen the 16 bolts in the sequence shown in the illustration and remove the bolts and 8 camshaft bearing caps.

  50. REMOVE NO. 3 CAMSHAFT SUB-ASSEMBLY

  51. REMOVE NO. 4 CAMSHAFT SUB-ASSEMBLY

  52. REMOVE CYLINDER HEAD SUB-ASSEMBLY

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  53. REMOVE CYLINDER HEAD GASKET

  54. REMOVE CYLINDER HEAD LH

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  55. REMOVE NO. 2 CYLINDER HEAD GASKET

  56. REMOVE NO. 1 WATER OUTLET PIPE


    1. A01LEWF

      Remove the knock sensor wire.

    2. for Type A:

      Remove the 3 bolts and No. 1 water outlet pipe.

    3. for Type B:

      Remove the bolt, 2 nuts and No. 1 water outlet pipe.

  57. REMOVE KNOCK SENSOR

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  58. REMOVE VALVE LIFTER


    1. Remove the 24 valve lifters.

      Tech Tips

      Arrange the removed parts so that they can be reinstalled in their original locations.

  59. REMOVE TAPER SCREW PLUG

    Note

    It is not necessary to remove a taper screw plug unless it is being replaced.

  60. REMOVE STUD BOLT

    Note

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