ENGINE UNIT DISASSEMBLY

PROCEDURE


  1. REMOVE SPARK PLUG

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  2. REMOVE CAMSHAFT POSITION SENSOR (for Intake Side)

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  3. REMOVE CAMSHAFT POSITION SENSOR (for Exhaust Side)

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  4. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY

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  5. REMOVE KNOCK SENSOR

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  6. REMOVE OIL PRESSURE SENDER GAUGE ASSEMBLY

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  7. REMOVE CRANKSHAFT POSITION SENSOR

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  8. REMOVE PCV VALVE (VENTILATION VALVE SUB-ASSEMBLY)

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  9. REMOVE NO. 1 VENTILATION CASE


    1. A01R4I1C05
      B0073AQ Bolt
      B0077IM Nut

      Remove the 6 bolts and 2 nuts.

    2. A01R7I6

      Using a screwdriver, remove the No. 1 ventilation case by prying between the No. 1 ventilation case and cylinder block sub-assembly.

      Note


      • Be careful not to damage the contact surfaces of the cylinder block sub-assembly.

      • Do not reuse the No. 1 ventilation case.

      Tech Tips

      Tape the screwdriver tip before use.

  10. REMOVE CRANKSHAFT PULLEY ASSEMBLY


    1. A01R4M1C04
      *a Hold
      *b Turn

      Using SST, hold the crankshaft pulley assembly and loosen the crankshaft pulley set bolt until 2 or 3 threads remain 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. A01R71IC04
      *1 Crankshaft Pulley Set Bolt
      *a Hold
      *b Turn

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

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

      Tech Tips

      Apply lubricant to the threads and end of SST.

  11. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A01R6GT

      Remove the 19 bolts and cylinder head cover sub-assembly from the camshaft housing sub-assembly.

    2. A01R3QRC02
      *1 Camshaft Bearing Cap Oil Hole Gasket
      *2 Gasket

      Remove the camshaft bearing cap oil hole gasket from the No. 1 camshaft bearing cap.

    3. Remove the gasket from the No. 2 camshaft bearing cap.

  12. REMOVE CYLINDER HEAD COVER GASKET


    1. A01R7HIC04
      *1 Cylinder Head Cover Gasket
      *2 No. 2 Cylinder Head Cover Gasket

      Remove the cylinder head cover gasket and No. 2 cylinder head cover gasket from the cylinder head cover sub-assembly.

  13. REMOVE SPARK PLUG TUBE GASKET


    1. A01R6TLC03
      *a Protective Tape

      Using a screwdriver, remove the spark plug tube gasket from the cylinder head cover sub-assembly.

      Note

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

      Tech Tips

      Tape the screwdriver tip before use.

  14. REMOVE CAMSHAFT TIMING OIL CONTROL SOLENOID ASSEMBLY

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  15. REMOVE ENGINE COOLANT TEMPERATURE SENSOR

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  16. REMOVE WATER OUTLET SUB-ASSEMBLY


    1. A01R3Y9

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

    2. Remove the 2 bolts, nut and water outlet sub-assembly from the timing chain cover assembly.

    3. Remove the O-ring from the timing chain cover assembly.

  17. REMOVE TIMING CHAIN COVER ASSEMBLY

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  18. REMOVE TIMING CHAIN COVER OIL SEAL

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  19. REMOVE TIMING CHAIN COVER PLATE


    1. A01R3JY

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

  20. SET NO. 1 CYLINDER TO TDC/COMPRESSION


    1. Temporarily install the crankshaft pulley set bolt.

    2. Rotate the crankshaft clockwise and align the timing marks (groove) on the camshaft timing gear assembly, camshaft timing exhaust gear assembly and crankshaft pulley set key of the crankshaft timing sprocket as shown in the illustration.

      A01R714C01
      *1 Crankshaft Pulley Set Key - -
      *a Approximately 7° *b Approximately 32°
      *c Timing Mark (Groove) - -

      Tech Tips

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

    3. Remove the crankshaft pulley set bolt.

  21. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY


    1. A01R3Z3C01
      *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. A01R5UKC01
      *a Pin

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

    3. A01R66R

      Remove the nut, bolt, No. 1 chain tensioner assembly and gasket from the cylinder block sub-assembly.

  22. REMOVE TIMING CHAIN GUIDE


    1. A01R5C2

      Remove the bolt and timing chain guide from the No. 1 camshaft bearing cap.

  23. REMOVE CHAIN TENSIONER SLIPPER


    1. A01R74Q

      Remove the bolt and chain tensioner slipper from the cylinder head sub-assembly.

  24. REMOVE CHAIN SUB-ASSEMBLY


    1. Remove the chain sub-assembly.

  25. REMOVE NO. 1 CHAIN VIBRATION DAMPER


    1. A01R5JA

      Remove the 2 bolts and No. 1 chain vibration damper from the cylinder head sub-assembly and cylinder block sub-assembly.

  26. REMOVE CRANKSHAFT TIMING SPROCKET


    1. A01R511

      Remove the crankshaft timing sprocket from the crankshaft.

  27. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY


    1. A01R46OC04
      *a Hold
      *b Turn

      Using a wrench to hold the hexagonal portion of the camshaft, remove the camshaft timing gear bolt and camshaft timing gear assembly from the camshaft.

      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.

  28. REMOVE CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY


    1. A01R7AEC04
      *a Hold
      *b Turn

      Using a wrench to hold the hexagonal portion of the camshaft, remove the bolt and camshaft timing exhaust gear assembly from the No. 2 camshaft.

      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.

  29. REMOVE OIL PIPE SUB-ASSEMBLY


    1. A01R7I0

      Remove the bolt and oil pipe sub-assembly from the No. 4 camshaft bearing cap.

  30. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY


    1. A01R3YZN04

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

    2. A01R66M

      Using a screwdriver, remove the camshaft housing sub-assembly by prying between the cylinder head sub-assembly and camshaft housing sub-assembly.

      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.

  31. REMOVE NO. 3 WATER BY-PASS PIPE


    1. A01R7B0

      Remove the 3 bolts, No. 3 water by-pass pipe and gasket from the cylinder head sub-assembly.

  32. REMOVE CAMSHAFT BEARING CAP


    1. A01R5UDN04

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

    2. Remove the No. 1 camshaft bearing cap, No. 2 camshaft bearing cap, No. 3 camshaft bearing cap and No. 4 camshaft bearing cap from the camshaft housing sub-assembly.

      Tech Tips

      Arrange the removed parts in the correct order.

  33. REMOVE OIL CONTROL VALVE FILTER


    1. A01R4K6

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

  34. REMOVE CAMSHAFT


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

  35. REMOVE NO. 2 CAMSHAFT


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

  36. REMOVE NO. 1 CAMSHAFT BEARING


    1. A01R683

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

  37. REMOVE NO. 2 CAMSHAFT BEARING


    1. A01R50L

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

  38. 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.

  39. 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.

  40. 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.

  41. REMOVE CYLINDER HEAD SUB-ASSEMBLY

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  42. REMOVE CYLINDER HEAD GASKET

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  43. REMOVE CYLINDER BLOCK WATER JACKET SPACER


    1. A01R6NS

      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.

  44. REMOVE OIL FILTER CAP ASSEMBLY

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  45. REMOVE OIL FILTER BRACKET CLIP


    1. A01R4OW

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

  46. REMOVE OIL COOLER ASSEMBLY

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  47. REMOVE OIL PAN DRAIN PLUG


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

  48. REMOVE OIL PAN SUB-ASSEMBLY


    1. A01R3H3

      Remove the 11 bolts and 2 nuts.

    2. A01R5Y2

      Insert the blade of an oil pan seal cutter between the oil pan sub-assembly and stiffening crankcase assembly, cut through 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.

  49. REMOVE ENGINE OIL LEVEL SENSOR

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  50. REMOVE OIL STRAINER SUB-ASSEMBLY


    1. A01R5CQ

      Remove the 3 bolts, oil strainer sub-assembly and gasket from the stiffening crankcase assembly and engine balancer assembly.

  51. REMOVE NO. 1 OIL PAN BAFFLE PLATE


    1. A01R6GW

      Remove the 4 bolts and No. 1 oil pan baffle plate from the engine balancer assembly.

  52. REMOVE ENGINE BALANCER ASSEMBLY


    1. A01R3GP

      Remove the 5 bolts and engine balancer assembly from the stiffening crankcase assembly.

      Note

      Do not disassemble the engine balancer assembly.

  53. REMOVE ENGINE OIL TEMPERATURE SENSOR

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  54. REMOVE STIFFENING CRANKCASE ASSEMBLY


    1. A01R57Q

      Remove the 8 bolts.

    2. A01R6XP

      Using a screwdriver with its tip wrapped with protective tape, 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.

  55. REMOVE REAR ENGINE OIL SEAL


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

  56. REMOVE STUD BOLT

    Note

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

  57. REMOVE RING PIN

    Tech Tips

    It is not necessary to remove the ring pins unless they are being replaced.