ENGINE UNIT DISASSEMBLY

PROCEDURE


  1. REMOVE WATER TEMPERATURE SENSOR

    A005KMXE04

    1. Using SST, remove the water temperature sensor and gasket.

      SST
      09817-33190

  2. REMOVE WATER OUTLET SUB-ASSEMBLY

    A005K0F

    1. Remove the 2 bolts, 2 nuts and water outlet sub-assembly.

    2. Remove the gasket from the cylinder head.

  3. REMOVE WATER INLET


    1. A005JZQ

      Remove the 3 bolts and the water inlet.

    2. Remove the gasket from the water inlet.

  4. REMOVE OIL PRESSURE SENDER GAGE ASSEMBLY

    A005KFLE02
    Text in Illustration
    *1 27 mm Deep Socket Wrench

    1. Using a 27 mm deep socket wrench, remove the oil pressure sender gage assembly.

  5. REMOVE OIL FILLER CAP SUB-ASSEMBLY


    1. Remove the oil filler cap from the cylinder head cover.

    2. Using a screwdriver with its tip wrapped in protective tape, remove the oil filler cap gasket.

  6. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A005HG1

      Remove the 12 bolts and the cylinder head cover.

    2. Remove the cylinder head cover gasket from the cylinder head cover.

  7. REMOVE ENGINE MOUNTING BRACKET RH


    1. A005JSU

      Remove the 4 bolts and the engine mounting bracket RH.

  8. REMOVE NO. 2 TIMING CHAIN COVER

    A005IOX

    1. Remove the bolt, manifold temperature sensor bracket and the No. 2 timing chain cover.

  9. REMOVE CRANKSHAFT DAMPER SUB-ASSEMBLY

    Click here

  10. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY


    1. A005MJS

      Remove the 20 bolts and the 2 nuts.

    2. A005LWRE01
      Text in Illustration
      *1 Protective Tape

      Using a screwdriver with its tip wrapped in protective tape, remove the timing chain cover sub-assembly by prying between the cylinder head and cylinder block.

      Note

      Do not damage the contact surfaces of the timing chain cover, cylinder head or cylinder block.

  11. REMOVE OIL PUMP GASKET


    1. A005MFY

      Remove the oil pump gasket.

  12. REMOVE OIL CHECK VALVE SUB-ASSEMBLY


    1. A005LIX

      Using a 6 mm hexagon wrench, remove the bolt and oil check valve sub-assembly from the timing chain cover sub-assembly.

  13. INSPECT OIL CHECK VALVE SUB-ASSEMBLY


    1. A005K92E01
      Text in Illustration
      *1 Ball

      Push the ball of the oil check valve sub-assembly to check if it is stuck.

      Note

      If the check valve is stuck, replace the oil check valve sub-assembly.

  14. REMOVE WATER INLET HOUSING

    A005M2O

    1. Remove the 3 bolts and the water inlet housing from the timing chain cover.

    2. Remove the gasket from the water inlet housing.

  15. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY

    Note

    Do not rotate the crankshaft with the chain tensioner removed.


    1. A005IA7E07
      Text in Illustration
      *1 Plunger
      *2 Groove
      *3 Hole
      *a Push

      Push in the plunger until the groove is aligned with the tensioner hole, and then insert a 1.1 mm (0.043 in.) diameter bar.

    2. A005M9Q

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

  16. REMOVE CHAIN TENSIONER SLIPPER


    1. A005HAU

      Remove the chain tensioner slipper.

  17. REMOVE NO. 1 CHAIN VIBRATION DAMPER


    1. A005IAU

      Using a 8 mm socket hexagon wrench, remove the 2 bolts and the No. 1 chain vibration damper.

  18. REMOVE CHAIN SUB-ASSEMBLY


    1. A005JVEE01

      Using SST, hold the camshaft timing sprocket.

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

    2. Remove the 3 bolts and the camshaft timing sprocket.

    3. A005LDH

      Remove the camshaft timing sprocket, crankshaft timing sprocket and chain together.

  19. REMOVE NO. 2 CHAIN SUB-ASSEMBLY

    A005JDB

    1. Remove the chain tensioner plate with the chain damper spring from the pin.

    2. A005KF7

      Insert a 4 mm (0.157 in.) diameter bar into the adjusting hole of the oil pump drive shaft gear to lock the gear in position, and then remove the nut.

    3. A005LXZ

      Remove the oil pump drive gear, oil pump drive shaft gear and No. 2 chain.

  20. REMOVE CHAIN DAMPER SPRING

    A005GNC

    1. Remove the chain damper spring from the chain tensioner plate.

  21. REMOVE CAMSHAFT

    Click here

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


    1. A005JTH

      Remove the No. 1 valve rocker arm from the cylinder head.

  23. REMOVE CYLINDER HEAD SUB-ASSEMBLY


    1. A005HGVE01

      Using several steps, loosen the 10 bolts in the order shown in the illustration, and then remove the bolts and washers.

      Note


      • When removing the bolts, do not drop the washers into the engine.

      • Removing the cylinder head bolts in the wrong order may cause damage to the cylinder head.

    2. Remove the cylinder head.

  24. REMOVE CYLINDER HEAD GASKET

    Click here

  25. REMOVE CYLINDER BLOCK WATER JACKET SPACER

    A005GLL

    1. Remove the cylinder block water jacket spacer from the cylinder block.

  26. REMOVE OIL FILTER CAP ASSEMBLY WITH ELEMENT

    A005IJHE01

    1. Using SST, remove the oil filter cap.

      SST
      09228-06501

  27. REMOVE OIL FILTER ELEMENT

    Click here

  28. REMOVE OIL COOLER ASSEMBLY

    A005I0Z

    1. Remove the 2 bolts, 2 nuts and oil cooler.

    2. A005GDA

      Remove the 2 O-rings and gasket from the oil filter bracket.

  29. REMOVE OIL FILTER BRACKET SUB-ASSEMBLY

    A005GMR

    1. Remove the 2 bolts and oil filter bracket from the oil pan.

    2. A005JJ6

      Remove the gasket from the oil pan.

  30. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY


    1. A005GM3

      Remove the oil pan drain plug and the gasket.

    2. Remove the 10 bolts and 2 nuts.

    3. A005J3PE04
      Text in Illustration
      *1 Oil Pan Seal Cutter

      Insert the oil pan seal cutter blade between the oil pan and No. 2 oil pan, and cut off the applied sealer.

      Note

      Do not damage the oil pan or No. 2 oil pan.

    4. Remove No. 2 oil pan.

  31. REMOVE ENGINE OIL LEVEL SENSOR

    A005I1Q

    1. Remove the 5 bolts and the engine oil level sensor.

  32. REMOVE OIL PAN SUB-ASSEMBLY


    1. A005MAK

      Remove the 12 bolts.

    2. A005IK0E04
      Text in Illustration
      *1 Protective Tape

      Using a screwdriver with its tip wrapped in protective tape, remove the oil pan by prying between the cylinder block and oil pan as illustrated.

      Note

      Do not apply excessive force when prying between the cylinder block and oil pan.

  33. REMOVE ENGINE REAR OIL SEAL


    1. A005LKA

      Remove the engine rear oil seal.