ENGINE UNIT DISASSEMBLY

PROCEDURE


  1. REMOVE SPARK PLUG

    Click here

  2. REMOVE OIL FILLER CAP SUB-ASSEMBLY


    1. B00415U

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

  3. REMOVE OIL FILLER CAP GASKET


    1. B00416DE10
      Text in Illustration
      *1 Protective Tape

      Using a screwdriver, remove the oil filler cap gasket from the oil filler cap.

      Tech Tips

      Wrap the screwdriver tip with protective tape before use.

  4. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE

    Click here

  5. REMOVE CAMSHAFT POSITION SENSOR

    Click here

  6. REMOVE O-RING

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  7. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY


    1. B0040Y0

      Remove the bolt and camshaft timing oil control valve assembly.

    2. B00412EE13

      Remove the O-ring from the camshaft timing oil control valve assembly.

  8. REMOVE KNOCK SENSOR


    1. B00410C

      Remove the bolt and knock sensor.

  9. REMOVE ENGINE COOLANT TEMPERATURE SENSOR


    1. B0040W1

      Using a 19 mm union nut wrench, remove the engine coolant temperature sensor and gasket.

  10. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY


    1. B00414E

      Using a 24 mm deep socket wrench, remove the engine oil pressure switch assembly.

  11. REMOVE OIL FILTER SUB-ASSEMBLY

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  12. REMOVE CRANKSHAFT POSITION SENSOR

    Click here

  13. REMOVE O-RING

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  14. REMOVE WATER INLET WITH THERMOSTAT SUB-ASSEMBLY


    1. B0040ZM

      Remove the 2 bolts and water inlet with thermostat sub-assembly.

    2. B0040X0

      Remove the gasket from the water inlet with thermostat sub-assembly.

  15. REMOVE ENGINE WATER PUMP ASSEMBLY


    1. B0040ZQ

      Remove the 5 bolts and engine water pump assembly.

    2. B00411V

      Remove the gasket from the engine water pump assembly.

  16. REMOVE WATER INLET HOUSING


    1. B004157

      Remove the bolt, 2 nuts and water inlet housing.

    2. Remove the gasket.

  17. REMOVE ENGINE MOUNTING BRACKET RH

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  18. REMOVE VENTILATION VALVE SUB-ASSEMBLY


    1. B0040WG

      Using a 19 mm deep socket wrench, remove the ventilation valve sub-assembly from the cylinder head cover sub-assembly.

  19. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY


    1. B0040U8

      Remove the 9 bolts, 2 seal washers, 2 nuts and cylinder head cover sub-assembly.

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

  20. REMOVE CRANKSHAFT DAMPER SUB-ASSEMBLY


    1. Set the No. 1 cylinder to TDC/compression.


      1. Turn the crankshaft damper until its notch and timing mark "0" of the timing chain cover are aligned.

      2. B0040UQE03
        Text in Illustration
        *a Timing Mark
        *b Timing Mark (Rectangle)
        *c Mark (Circle)
        *d Timing Notch

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

        Tech Tips


        • There are 3 marks on the camshaft timing sprocket. Make sure that the timing mark (rectangle) is at the top.

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

    2. B0040U1E02
      Text in Illustration
      *a Hold
      B004123 Turn

      Using SST, hold the crankshaft damper sub-assembly in place and loosen the bolt.

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

      Note

      When installing SST, be careful that the bolt which holds SST does not interfere with the chain cover.

    3. Remove the crankshaft damper sub-assembly and bolt.

    4. B004145

      Remove the crankshaft straight pin.

  21. REMOVE TIMING CHAIN COVER

    Click here

  22. REMOVE SCREW PLUG

    Click here

  23. REMOVE OIL PUMP SEAL

    Click here

  24. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY

    Click here

  25. REMOVE CHAIN TENSIONER SLIPPER

    Click here

  26. REMOVE NO. 1 CHAIN VIBRATION DAMPER

    Click here

  27. REMOVE CHAIN SUB-ASSEMBLY

    Click here

  28. REMOVE FUEL DELIVERY PIPE


    1. B00415V

      Remove the 3 bolts and fuel delivery pipe.

  29. REMOVE FUEL DELIVERY SPACER

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  30. REMOVE INJECTOR VIBRATION INSULATOR

    Click here

  31. REMOVE FUEL INJECTOR ASSEMBLY

    Click here

  32. REMOVE NO. 2 CAMSHAFT


    1. B0040YHE03

      Using several steps, uniformly loosen and remove the 11 bolts in the sequence shown in the illustration. Then remove the No. 1 camshaft bearing cap and 4 No. 2 camshaft bearing caps.

      Note

      Uniformly loosen the bolts while keeping the No. 2 camshaft level.

  33. REMOVE CAMSHAFT TIMING GEAR OR SPROCKET


    1. B0040YE

      Clamp the No. 2 camshaft in a vise.

      Note

      Be careful not to damage the No. 2 camshaft.

    2. Remove the bolt and camshaft timing gear or sprocket.

  34. REMOVE CAMSHAFT


    1. B004146E03

      Using several steps, uniformly loosen and remove the 8 bolts in the sequence shown in the illustration. Then remove the 4 No. 2 camshaft bearing caps.

      Note

      Uniformly loosen the bolts while keeping the camshaft level.

  35. INSPECT CAMSHAFT TIMING GEAR ASSEMBLY

    Click here

  36. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY

    Click here

  37. REMOVE CYLINDER HEAD SUB-ASSEMBLY

    Click here

  38. REMOVE CYLINDER HEAD GASKET

    Click here

  39. REMOVE OIL FILTER UNION


    1. B0040Z1

      Using a 12 mm hexagon socket wrench, remove the oil filter union.

  40. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY


    1. B004120

      Remove the oil pan drain plug and gasket.

    2. Remove the 9 bolts and 2 nuts.

    3. B00412J

      Insert the blade of an oil pan seal cutter between the oil pan and No. 2 oil pan sub-assembly, cut the sealer and remove the No. 2 oil pan sub-assembly.

      Note

      Be careful not to damage the oil pan and No. 2 oil pan sub-assembly.

  41. REMOVE OIL STRAINER SUB-ASSEMBLY


    1. B004149

      Remove the bolt, 2 nuts, oil strainer sub-assembly and gasket.

  42. REMOVE OIL PAN SUB-ASSEMBLY


    1. B0040TZ

      Loosen and remove the 13 bolts uniformly in several steps.

    2. B00411ME03
      Text in Illustration
      *1 Protective Tape

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

      Note

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

      Tech Tips

      Wrap the screwdriver tip with protective tape before use.

    3. B0040Y9

      Remove the 2 O-rings from the cylinder block.

    4. B0040XC

      Using an E5 "TORX" socket wrench, remove the 4 stud bolts.

  43. REMOVE REAR ENGINE OIL SEAL


    1. B0040V4

      Remove the rear engine oil seal.