БЛОК ДВИГАТЕЛЯ РАЗБОРКА


  1. REMOVE OIL PRESSURE SENDER GAUGE ASSEMBLY


    1. A0158EO

      Disconnect the sender gauge connector.

    2. A015AHE

      Remove the oil pressure sender gauge.

  2. REMOVE OIL FILTER ELEMENT


    1. A015A6BE10
      Text in Illustration
      *1 Pipe
      *2 Hose

      Connect a hose with an inside diameter of 15 mm (0.591 in.) to the pipe.

    2. A01565V

      Remove the oil filter drain plug.

    3. A01567FE01
      Text in Illustration
      *1 Cap
      *2 Valve
      *3 Pipe
      *4 O-Ring
      *5 Hose

      Install the pipe to the oil filter cap.

      Note

      If the O-ring is removed with the drain plug, install the O-ring together with the pipe.

      Tech Tips

      Use a container to catch the draining oil.

    4. A0158W3

      Check that oil is drained from the oil filter. Then disconnect the pipe and remove the O-ring as shown in the illustration.

    5. A0155MKE02
      Text in Illustration
      *1 Oil Filter Bracket Clip

      Using SST, remove the oil filter cap.

      SST
      09228-06501

      Note

      Do not remove the oil filter bracket clip.

    6. A015DDVE02
      Text in Illustration
      *1 Oil Filter Element
      *2 O-Ring

      Remove the oil filter element and O-ring from the oil filter cap.

      Note

      Be sure to remove the cap O-ring by hand, without using any tools, to prevent damage to the cap O-ring groove.

  3. REMOVE NO. 1 OIL COOLER BRACKET


    1. A0156D4

      Remove the 2 nuts and bracket.

    2. Disconnect the ground wire from the cylinder block.

  4. REMOVE OIL FILTER BRACKET


    1. A015AXQ

      Remove the 2 bolts, 2 nuts and filter bracket.

    2. A0156ZM

      Remove the 2 O-rings.

  5. REMOVE OIL FILLER CAP SUB-ASSEMBLY

  6. REMOVE OIL FILLER CAP HOUSING


    1. A015814

      Remove the 2 bolts, filler cap housing and gasket.

  7. REMOVE SPARK PLUG


    1. Using a 16 mm plug wrench, remove the 8 spark plugs.

  8. REMOVE VVT SENSOR


    1. A015CAU

      LH:

      Remove the 2 bolts and 2 VVT sensors.

    2. A015A7S

      RH:

      Remove the 2 bolts and 2 VVT sensors.

  9. REMOVE CAMSHAFT POSITION SENSOR


    1. A0157RP

      Remove the bolt and camshaft position sensor.

  10. REMOVE CRANK POSITION SENSOR PROTECTOR

    A0157L1

    1. Remove the 2 bolts and sensor protector.

  11. REMOVE CRANKSHAFT POSITION SENSOR


    1. A0157VO

      Remove the bolt and crankshaft position sensor.

  12. REMOVE ENGINE OIL LEVEL SENSOR


    1. Disconnect the oil level sensor connector.

    2. A015A0I

      Remove the 4 bolts and oil level sensor.

    3. A0159LQE01
      Text in Illustration
      *1 Cutting Position
      *2 Supply Part

      Cut off the gasket as shown in the illustration.

    4. Remove the gasket from the oil level sensor.

      Tech Tips

      After cutting away the parts of the gasket shown in the illustration, remove only the outer part of the gasket.

  13. REMOVE CAMSHAFT OIL CONTROL VALVE ASSEMBLY


    1. A0155O4

      LH:

      Remove the 2 bolts and 2 oil control valves.

    2. A015CQU

      RH:

      Remove the 2 bolts and 2 oil control valves.

  14. REMOVE WATER PUMP PULLEY


    1. A015BB7E03

      Using SST, hold the water pump pulley.

      SST
      09960-10010   ( 09962-01000, 09963-01000 )

    2. Remove the 4 bolts and water pump pulley.

  15. REMOVE NO. 1 IDLER PULLEY SUB-ASSEMBLY


    1. A0155P5

      Remove the bolt and idler pulley.

  16. REMOVE FLUID COUPLING BRACKET


    1. A015BB4

      Remove the 4 bolts and fluid coupling bracket.

  17. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY


    1. A01560I

      Remove the standard bolt, 6 mm hexagon wrench bolt and belt tensioner.

  18. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH


    1. A0155S9

      Remove the 14 bolts, seal washer, cylinder head cover and gasket.

      Tech Tips

      Make sure the removed parts are returned to the same places they were removed from.

    2. A0157F1

      Remove the 5 gaskets from the camshaft bearing caps (No. 2, No. 3).

  19. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY RH


    1. A0158AB

      Remove the bolt and noise filter.

    2. A015BOE

      Remove the 14 bolts, seal washer, cylinder head cover and gasket.

      Tech Tips

      Make sure the removed parts are returned to the same places they were removed from.

    3. A0157OB

      Remove the 5 gaskets from the camshaft bearing caps (No. 1, No. 3).

  20. REMOVE OIL CONTROL VALVE FILTER


    1. A015D8ME03
      Text in Illustration
      *1 Cylinder Head Cover Spacer
      *2 Gasket
      *3 Filter

      LH:

      Remove the 3 bolts, cylinder head cover spacer, gasket and filter.

    2. A0158UTE03
      Text in Illustration
      *1 Cylinder Head Cover Spacer
      *2 Gasket
      *3 Filter

      RH:

      Remove the 3 bolts, cylinder head cover spacer, gasket and filter.

  21. REMOVE SPARK PLUG TUBE GASKET

    A015B92E02
    Text in Illustration
    *1 Tape
    A015DIT Pry

    1. Bend the 4 ventilation baffle plate claws on the cylinder head cover to an angle of 90° or more.

    2. Using a screwdriver, pry out the gaskets.

      Note


      • Be careful not to damage the cylinder head cover.

      • Be careful not to damage the gasket when removing it, as the removed gasket needs to be used when installing a new one.

      Tech Tips

      Tape the screwdriver tip before use.

  22. REMOVE CRANKSHAFT PULLEY


    1. A0157O6E04
      Text in Illustration
      *a Hold
      A015DIT Turn

      Using SST, loosen the crankshaft pulley set bolt until 2 or 3 threads are engaged.

      SST
      09213-70011
      09330-00021
    2. A0156JUE03
      Text in Illustration
      *a Hold
      A015DIT Turn

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

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

  23. REMOVE WATER PUMP ASSEMBLY


    1. A015E4W

      Remove the 8 bolts, water pump and gasket.

  24. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY


    1. A01595X

      Remove the 28 bolts and nut shown in the illustration.

      Text in Illustration
      A015DIT Bolt
      A015CC1 Nut
    2. A015B5A

      Remove the timing chain cover by prying between the timing chain cover and cylinder head or cylinder block with a screwdriver as shown in the illustration.

      Note

      Be careful not to damage the contact surfaces of the cylinder head, cylinder block and chain cover.

      Tech Tips

      Tape the screwdriver tip before use.

    3. A0157TF

      Remove the oil pump gasket from the cylinder block.

    4. A0155SQ

      Remove the O-ring from the oil pan.

  25. REMOVE WATER INLET PIPE


    1. A0158TJ

      Remove the water inlet pipe.

    2. Remove the 2 O-rings from the water inlet pipe.

  26. REMOVE FRONT CRANKSHAFT OIL SEAL


    1. A0156VXE02
      Text in Illustration
      *1 Wooden Block

      Place the timing chain cover on wooden blocks.

    2. Using a screwdriver and wooden block, pry out the oil seal.

      Note

      Do not damage the surface of the oil seal press fit hole.

      Tech Tips

      Tape the screwdriver tip before use.

  27. SET NO. 1 CYLINDER TO TDC/COMPRESSION


    1. Temporarily install the crankshaft pulley bolt.

    2. Rotate the crankshaft clockwise so that the timing marks on the crankshaft timing sprocket and camshaft timing gears are as shown in the illustration.

      Tech Tips

      If the timing marks do not align, rotate the crankshaft clockwise again and align the timing marks.

      A0156GJE02
      Text in Illustration
      *1 Timing Mark *2 Timing Mark Position
      *3 Knock Pin Position *4 Key
      *a Toward Ceiling *b Approximately 2°
      *c Approximately 45° *d Approximately 16°
      *e Approximately 18° *f Approximately 32°

  28. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY LH


    1. A015A46E02
      Text in Illustration
      *1 Plunger
      *2 Stopper Plate

      Move the stopper plate clockwise to release the lock, and push the plunger deep into the tensioner.

    2. A015DSXE02
      Text in Illustration
      *1 Plunger
      *2 Stopper Plate

      Move the stopper plate counterclockwise to set the lock, and insert a hexagon wrench into the stopper plate hole.

    3. A015755

      Remove the 2 bolts, chain tensioner and gasket.

  29. REMOVE NO. 1 CHAIN TENSIONER SLIPPER LH

    A0157UA

  30. REMOVE NO. 1 CHAIN VIBRATION DAMPER LH

    A015CCX

    1. Remove the 2 bolts and chain vibration damper.

  31. REMOVE NO. 1 CHAIN SUB-ASSEMBLY LH


    1. A0158J7E02
      Text in Illustration
      *1 Pin
      *2 Plunger
      *a Push

      While pushing down the No. 3 chain tensioner, insert a pin of 1.0 mm (0.0394 in.) into the hole to fix it in place.

    2. A015A4RE02
      Text in Illustration
      *a Hold
      A015DIT Turn

      Hold the hexagonal portion of the camshaft with a wrench and loosen the bolt.

      Note


      • Be careful not to damage the cylinder head with the wrench.

      • Do not disassemble the camshaft timing gear.

    3. A0156ZJE02
      Text in Illustration
      *a Hold
      A015DIT Turn

      Hold the hexagonal portion of the camshaft with a wrench and loosen the bolt.

      Note

      Be careful not to damage the cylinder head with the wrench.

    4. Remove the 2 bolts. Then with the No. 1 and No. 2 chains still connected to the gears, remove the camshaft timing gear, camshaft timing exhaust gear and crankshaft timing sprocket LH.

    5. Remove the No. 1 and No. 2 chains from the gears.

  32. REMOVE NO. 3 CHAIN TENSIONER ASSEMBLY

    A015AMNE01

    1. Remove the 2 bolts and chain tensioner.

  33. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY RH


    1. A015B2PE02
      Text in Illustration
      *1 Plunger
      *2 Stopper Plate

      Move the stopper plate clockwise to release the lock, and push the plunger deep into the tensioner.

    2. A0157NFE02
      Text in Illustration
      *1 Plunger
      *2 Stopper Plate

      Move the stopper plate counterclockwise to set the lock, and insert a hexagon wrench into the stopper plate hole.

    3. A015C5P

      Remove the 2 bolts and chain tensioner.

  34. REMOVE NO. 1 CHAIN TENSIONER SLIPPER RH

    A015A8N

  35. REMOVE NO. 1 CHAIN VIBRATION DAMPER RH

    A0155IM

    1. Remove the 2 bolts and vibration damper.

  36. REMOVE NO. 1 CHAIN SUB-ASSEMBLY RH


    1. A015E4RE02
      Text in Illustration
      *1 Pin
      *2 Plunger
      *a Push

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

    2. A015B0CE02
      Text in Illustration
      *a Hold
      A015DIT Turn

      Hold the hexagonal portion of the camshaft with a wrench and loosen the bolt.

      Note


      • Be careful not to damage the cylinder head with the wrench.

      • Do not disassemble the camshaft timing gear.

    3. A0156CXE02
      Text in Illustration
      *a Hold
      A015DIT Turn

      Hold the hexagonal portion of the camshaft with a wrench and loosen the bolt.

      Note

      Be careful not to damage the cylinder head with the wrench.

    4. Remove the 2 bolts. Then with the No. 1 and No. 2 chains still connected to the gears, remove the camshaft timing gear, camshaft timing exhaust gear and crankshaft timing sprocket RH.

    5. Remove the No. 1 and No. 2 chains from the gears.

  37. REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY

    A0159WKE01

    1. Remove the 2 bolts and chain tensioner.

  38. REMOVE CRANKSHAFT TIMING GEAR KEY

    A01574N

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

  39. REMOVE CAMSHAFT BEARING CAP LH


    1. A015BEDE03
      Text in Illustration
      *1 IN
      *2 EX
      *3 Knock Pin

      Make sure that the knock pin of the camshaft is positioned as shown in the illustration.

    2. A015BV1E03

      Uniformly loosen and remove the 10 bearing cap bolts in the sequence shown in the illustration.

    3. A0158AOE03

      Uniformly loosen and remove the 18 bearing cap bolts in the sequence shown in the illustration.

      Note

      Uniformly loosen the bolts while keeping the camshaft level.

    4. Remove the 6 bearing caps.

      Tech Tips

      Arrange the removed parts in the correct order.

    5. Remove the No. 3 and No. 4 camshafts.

  40. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY LH


    1. A0157MK

      Remove the camshaft housing by prying between the cylinder head and camshaft housing with a screwdriver.

      Note

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

      Tech Tips

      Tape the screwdriver tip before use.

  41. REMOVE CAMSHAFT BEARING CAP RH


    1. A0157ZFE03
      Text in Illustration
      *1 EX
      *2 IN
      *3 Knock Pin

      Make sure that the knock pin of the camshaft is positioned as shown in the illustration.

    2. A015CH9E03

      Uniformly loosen and remove the 10 bearing cap bolts in the sequence shown in the illustration.

    3. A015AT2E03

      Uniformly loosen and remove the 18 bearing cap bolts in the sequence shown in the illustration.

      Note

      Uniformly loosen the bolts while keeping the camshaft level.

    4. Remove the 6 bearing caps.

      Tech Tips

      Arrange the removed parts in the correct order.

    5. Remove the No. 1 and No. 2 camshafts.

  42. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY RH


    1. A015CD7

      Remove the camshaft housing by prying between the cylinder head and camshaft housing with a screwdriver.

      Note

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

      Tech Tips

      Tape the screwdriver tip before use.

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


    1. Remove the 32 valve rocker arms from the cylinder heads.

      Tech Tips

      Arrange the removed parts in the correct order.

  44. REMOVE VALVE LASH ADJUSTER ASSEMBLY


    1. Remove the 32 valve lash adjusters from the cylinder heads.

      Tech Tips

      Arrange the removed parts in the correct order.

  45. REMOVE VALVE STEM CAP


    1. Remove the 32 valve stem caps from the cylinder heads.

      Tech Tips

      Arrange the removed parts in the correct order.

  46. REMOVE CYLINDER HEAD SUB-ASSEMBLY LH


    1. A01554AE05

      Uniformly loosen and remove the 2 bolts in the sequence shown in the illustration.

    2. A0159FJE05

      Using a 10 mm bi-hexagon wrench, uniformly loosen the 10 cylinder head bolts in the sequence shown in the illustration. Remove the 10 cylinder head bolts and plate washers.

      Note


      • Be careful not to drop washers into the cylinder head.

      • Head warpage or cracking could result from removing bolts in an incorrect order.

      Tech Tips

      Be sure to arrange the removed parts for each installation position separately.

    3. Remove the cylinder head and gasket.

  47. REMOVE CYLINDER HEAD SUB-ASSEMBLY RH


    1. A01571FE04

      Uniformly loosen and remove the 2 bolts in the sequence shown in the illustration.

    2. A0158VTE03

      Using a 10 mm bi-hexagon wrench, uniformly loosen the 10 cylinder head bolts in the sequence shown in the illustration. Remove the 10 cylinder head bolts and plate washers.

      Note


      • Be careful not to drop washers into the cylinder head.

      • Head warpage or cracking could result from removing bolts in an incorrect order.

      Tech Tips

      Be sure to arrange the removed parts for each installation position separately.

    3. Remove the cylinder head and gasket.

  48. REMOVE CYLINDER BLOCK WATER JACKET SPACER

    A0158E1

    1. Remove the 2 water jacket spacers from the cylinder block.

      Note

      Be sure to remove the water jacket spacers. If not, they may fall and become damaged when the cylinder block is inverted.

  49. REMOVE VENTILATION PIPE GASKET


    1. A0158L6

      Using a screwdriver, pry out the ventilation pipe gasket.

      Tech Tips

      Tape the screwdriver tip before use.

  50. REMOVE NO. 1 HEAT EXCHANGER COVER


    1. A0159ZS

      Remove the 12 bolts and 2 nuts.

      Text in Illustration
      A015DIT Bolt
      A015CC1 Nut
    2. A0159PN

      Remove the heat exchanger by prying between the heat exchanger and cylinder block with a screwdriver.

      Tech Tips

      Tape the screwdriver tip before use.

  51. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY


    1. A0156QF

      Remove the 14 bolts and 2 nuts.

      Text in Illustration
      A015DIT Bolt
      A015CC1 Nut
    2. A015BAU

      Insert the blade of an oil pan seal cutter between the oil pans. Cut through the applied sealer and remove the No. 2 oil pan.

      Note

      Be careful not to damage the contact surfaces of the oil pans.

  52. REMOVE NO. 1 OIL PAN SUB-ASSEMBLY


    1. A01566B

      Remove the 14 bolts and 2 nuts.

      Text in Illustration
      A015DIT Bolt
      A015CC1 Nut

      Tech Tips

      Be sure to clean the bolts and stud bolts, and check the threads for cracks or other damage.

    2. A0158V1E03
      Text in Illustration
      *A LH Side
      *B RH Side

      Remove the oil pan by prying between the oil pan and cylinder block with a screwdriver.

      Note

      Be careful not to damage the contact surfaces of the cylinder block and oil pan.

      Tech Tips

      Tape the screwdriver tip before use.

  53. REMOVE NO. 1 OIL PAN BAFFLE PLATE


    1. A015737

      Remove the 7 bolts and baffle plate.

  54. REMOVE OIL STRAINER SUB-ASSEMBLY


    1. A015AEI

      Remove the 2 bolts, oil strainer and O-ring.

  55. REMOVE ENGINE REAR OIL SEAL RETAINER


    1. A015CJC

      Remove the 6 bolts and oil seal retainer.

    2. A015BCZ

      Using a screwdriver, pry out the oil seal retainer.

      Tech Tips

      Tape the screwdriver tip before use.

  56. REMOVE OIL DRAIN PIPE SUB-ASSEMBLY


    1. A0157E2

      Remove the bolt and oil drain pipe.

    2. Remove the O-ring.

  57. REMOVE REAR CRANKSHAFT OIL SEAL


    1. A0159KKE02
      Text in Illustration
      *1 Wooden Block

      Place the oil seal retainer on wooden blocks.

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

  58. REMOVE RING PIN

    Note

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

  59. REMOVE STUD BOLT

    Note

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