ENGINE UNIT DISASSEMBLY

PROCEDURE


  1. REMOVE OIL FILLER CAP SUB-ASSEMBLY


    1. A005P97

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

  2. REMOVE OIL FILLER CAP GASKET


    1. A005OQN

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

  3. REMOVE ENGINE COVER JOINT


    1. A005ONJ

      Remove the 2 engine cover joints.

  4. REMOVE SPARK PLUG

    Click here

  5. REMOVE CAMSHAFT POSITION SENSOR


  6. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY


  7. REMOVE CRANKSHAFT POSITION SENSOR

    Click here

  8. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY

    Click here

  9. REMOVE KNOCK SENSOR

    Click here

  10. REMOVE ENGINE COOLANT TEMPERATURE SENSOR

    Click here

  11. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A005PMS

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

    2. A005OO2

      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. A005QDR

      Remove the cylinder head cover gasket.

  13. REMOVE SPARK PLUG TUBE GASKET


    1. A005OO5

      Pry up the 4 claws of the ventilation baffle plate.

      Note

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

    2. Remove the 4 spark plug tube gaskets from the cylinder head cover sub-assembly.

      Note

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

      Tech Tips

      Prevent the spark plug tube gaskets from being deformed as much as possible. The removed spark plug tube gaskets will be used when installing new spark plug tube gaskets.

  14. REMOVE OIL FILTER CAP ASSEMBLY

    Click here

  15. REMOVE OIL FILTER BRACKET CLIP


    1. A005OIL

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

  16. SET NO. 1 CYLINDER TO TDC/COMPRESSION


    1. A005PEQC04
      *a Timing Mark
      *b Timing Notch

      Turn the crankshaft pulley 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 not, turn the crankshaft 1 complete revolution (360°) and align the marks as above.

  17. REMOVE CRANKSHAFT PULLEY

    Click here

  18. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY


    1. A005OXA

      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.

  19. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY

    Click here

  20. REMOVE TIMING CHAIN COVER OIL SEAL

    Click here

  21. REMOVE WATER INLET HOUSING


    1. A005PNX

      Remove the 3 bolts, water inlet housing and gasket.

  22. REMOVE NO. 1 GENERATOR BRACKET


    1. A005PAU

      Remove the 4 bolts and No. 1 generator bracket.

  23. REMOVE CHAIN TENSIONER SLIPPER


    1. A005ODR

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

  24. REMOVE NO. 1 CHAIN VIBRATION DAMPER


    1. A005Q0E

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

  25. REMOVE CHAIN SUB-ASSEMBLY


    1. A005PC2

      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. A005QAG

      Remove the No. 1 crankshaft position sensor plate.

  29. REMOVE CRANKSHAFT TIMING GEAR KEY


    1. A005PI4C23
      *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

    Click here

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


    1. A005P5E

      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. A005PFS

      Remove the 16 valve lash adjuster assemblies.

      Tech Tips

      Arrange the removed parts in the correct order.

  40. REMOVE VALVE STEM CAP


    1. A005PDR

      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 (VENTILATION VALVE SUB-ASSEMBLY)

    Click here

  45. REMOVE OIL PAN DRAIN PLUG


    1. A005P9L

      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. A005PGV

      Uniformly loosen and remove the 11 bolts.

    2. A005Q1EC10
      *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. A005OLU

      Remove the 2 No. 1 taper screw plugs.

  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.