ENGINE UNIT DISASSEMBLY

PROCEDURE


  1. REMOVE SPARK PLUG

    A005LYA

    1. Using a spark plug wrench, remove the 4 spark plugs.

  2. REMOVE KNOCK SENSOR

    A005K9E

    1. Remove the nut and the knock sensor.

  3. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY

    A005L3P

    1. Using a 24 mm (0.94 in.) deep socket wrench, remove the oil pressure switch.

  4. REMOVE ENGINE COOLANT TEMPERATURE SENSOR

    A005J27E01

    1. Using SST, remove the engine coolant temperature sensor.

      SST
      09817-33190

  5. REMOVE WATER INLET

    A005H7U

    1. Remove the 2 nuts and the water inlet.

  6. REMOVE THERMOSTAT

    A005KO6

    1. Remove the thermostat.

    2. Remove the gasket from the thermostat.

  7. REMOVE OIL FILLER CAP SUB-ASSEMBLY

    A005KFK

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

  8. REMOVE OIL FILLER CAP GASKET

    A005HBWE07
    Text in Illustration
    *1 Protective Tape

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

  9. REMOVE CRANKSHAFT POSITION SENSOR


    1. Remove the bolt and the crankshaft position sensor.

  10. REMOVE VENTILATION VALVE SUB-ASSEMBLY

    A005M9M

    1. Remove the ventilation valve from the cylinder head cover.

  11. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY

    A005M1P

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

  12. REMOVE CYLINDER HEAD COVER GASKET


    1. Remove the gasket from the cylinder head cover.

  13. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY

    A005HOR

    1. Remove the bolt and the camshaft timing oil control valve.

  14. REMOVE WATER PUMP PULLEY

    A005LQCE01

    1. Using SST, hold the pump pulley.

      SST
      09960-10010   ( 09962-01000, 09963-00700 )

    2. Remove the 3 bolts and the pump pulley.

  15. REMOVE CRANKSHAFT DAMPER SUB-ASSEMBLY

    A005HWTE06

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


      1. Turn the crankshaft damper sub-assembly, and align its timing notch with timing mark "0" of the oil pump.

        Text in Illustration
        *a Timing Notch
      2. A005HQ5E20
        Text in Illustration
        *a Timing Marks

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

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

    2. A005IS4E01

      Using 2 SST, loosen the bolt while holding the crankshaft damper sub-assembly.

      SST
      09213-14010   ( 91651-60865 )
      09330-00021

      Note

      Check the SST installation positions when installing them, to avoid the SST fixing bolts from coming into contact with the oil pump assembly.

    3. Remove the SSTs and the bolt.

    4. Remove the crankshaft damper sub-assembly.

  16. REMOVE TRANSVERSE ENGINE ENGINE MOUNTING BRACKET

    A005GX7

    1. Remove the 4 bolts and the transverse engine engine mounting bracket.

  17. REMOVE WATER PUMP ASSEMBLY

    A005H2Y

    1. Remove the 3 bolts and 2 nuts and the water pump and gasket.

  18. REMOVE OIL PUMP ASSEMBLY

    A005HNU

    1. Remove the 15 bolts and nut.

    2. A005K8HE01
      Text in Illustration
      *1 Protective Tape

      Using a screwdriver with its tip wrapped in protective tape, prize the oil pump assembly to remove it.

      Note

      Do not damage the contact surface of the oil pump assembly and oil pan sub-assembly.

    3. A005KOK

      Remove the 2 O-rings from the cylinder block and oil pan sub-assembly.

  19. REMOVE OIL PUMP SEAL

    A005HUME02
    Text in Illustration
    *1 Wooden Blocks
    *2 Protective Tape

    1. Using a screwdriver with its tip wrapped in protective tape, remove the oil seal.

  20. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY

    A005JN4E04
    Text in Illustration
    *1 Oil jet
    *a Timing Mark

    Note


    • Do not rotate the crankshaft with the chain tensioner removed.

    • When rotating the camshaft with the timing chain removed, rotate the crankshaft counterclockwise 40° from the TDC first.


    1. A005GIWE02
      Text in Illustration
      *1 Stopper Plate

      Pull up the stopper plate and hold it with its lock released.

    2. A005IE0E02
      Text in Illustration
      *1 Plunger

      Unlock the plunger of the tensioner and push it in to the end.

    3. A005HQWE02
      Text in Illustration
      *1 Stopper Plate

      Pull down the stopper plate with the plunger pushed to the end and lock the plunger.

    4. A005JL5

      Insert a 3 mm (0.12 in.) diameter bar into the hole in the stopper plate and lock the plunger.

    5. A005LWB

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

  21. REMOVE CHAIN TENSIONER SLIPPER

    A005GZQ

    1. Remove the chain tensioner slipper.

  22. REMOVE NO. 1 CHAIN VIBRATION DAMPER

    A005GO9

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

  23. REMOVE CHAIN SUB-ASSEMBLY

  24. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY

    A005HPF

    1. Remove the 3 bolts and remove the fuel delivery pipe sub-assembly together with the 4 fuel injectors.

      Note

      Do not drop the fuel injectors when removing the fuel delivery pipe sub-assembly.

  25. REMOVE NO. 1 DELIVERY PIPE SPACER

    A005MGU

    1. Remove the 2 No. 1 delivery pipe spacers.

  26. REMOVE INJECTOR VIBRATION INSULATOR

    A005L69

    1. Remove the 4 injector vibration insulators.

  27. REMOVE FUEL INJECTOR ASSEMBLY

    A005IGC

    1. Pull the 4 fuel injector assemblies out of the fuel delivery pipe sub-assembly.

  28. REMOVE CAMSHAFT POSITION SENSOR

    A005I4P

    1. Remove the bolt and the camshaft position sensor.

  29. REMOVE NO. 2 CAMSHAFT

    A005JN4E05
    Text in Illustration
    *1 Oil jet
    *a Timing Mark

    Note

    When rotating the camshaft with the timing chain removed, rotate the crankshaft counterclockwise 40° from the TDC first, and align the oil jet hole with the paint mark. This prevents the pistons from coming into contact with the valves.


    1. A005HFRE01

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

      Note

      Loosen each bolt uniformly while keeping the camshaft level.

  30. REMOVE CAMSHAFT TIMING SPROCKET

    A005M49

    1. Clamp the camshaft in a vise.

    2. Remove the fringe bolt and the camshaft timing sprocket.

      Note

      Do not damage the camshaft.

  31. REMOVE CAMSHAFT

    A005ME2E01

    1. Using several steps, loosen and remove the 8 bearing cap bolts uniformly in the sequence shown in the illustration, then remove the No. 2 camshaft bearing cap and the camshaft.

      Note

      Loosen each bolt uniformly keeping the camshaft level.

  32. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY


    1. Clamp the camshaft in a vise, and confirm that it is locked.

      Note

      Do not damage the camshaft.

    2. A005M2ZE19
      Text in Illustration
      *1 Rubber Piece
      *2 Vinyl Tape
      *a Advance Side Path
      *b Retard Side Path
      *c Open
      *d Close

      Cover the 4 oil paths of the cam journal with tape as shown in the illustration.

      Tech Tips

      One of the 2 grooves located on the cam journal is for retarding cam timing (upper) and the other is for advancing cam timing (lower). Each groove has 2 oil paths. Plug one of the oil paths for each groove with a piece rubber before wrapping the cam journal with the tape.

    3. Puncture the tape covering the advance oil path and the retard oil path on the opposite side from the advance oil path.

    4. A005M6FE04
      Text in Illustration
      *a Advance Side Path
      *b Retard Side Path

      Apply compressed air at about 150 kPa (1.5 kgf*cm2) pressure into the 2 broken paths (the advance side path and the retard side path).

      Note

      Cover the paths with a piece of cloth to prevent oil splashes.

    5. A005KUJE04
      Text in Illustration
      *a Advance Side Path
      *b Retard Side Path
      *c Hold Pressure
      *d Decompress

      Confirm that the camshaft timing gear assembly revolves in the timing advance direction when the air pressure on the timing retard path is reduced.

      Tech Tips

      The lock pin is released and the camshaft timing gear revolves in the advance direction.

    6. When the camshaft timing gear reaches the most advanced position, release the air pressure on the timing retard side path, and then release the air pressure on the timing advance side path.

      Note

      Camshaft timing gear assembly occasionally shifts to the retard side abruptly if the air pressure on the advance side path is released first. It often results in the breakage of the lock pin.

    7. A005GIYE02
      Text in Illustration
      *1 Flange Bolt

      Remove the fringe bolt and remove the camshaft timing gear assembly.

      Note


      • Do not remove the other 4 bolts.

      • When reusing the camshaft timing gear, unlock the lock pin inside the camshaft timing gear first.

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

    Click here

  34. REMOVE VALVE LASH ADJUSTER ASSEMBLY

    Click here

  35. REMOVE VALVE STEM CAP

    Click here

  36. REMOVE CYLINDER HEAD SUB-ASSEMBLY

    A005GQA

    1. Using several steps, loosen and remove the 10 cylinder head bolts uniformly with an 8 mm (0.31 in.) bi-hexagon wrench in the sequence shown in the illustration. Remove the 10 cylinder head bolts and the plate washers.

      Note


      • Do not drop the washers into the cylinder head.

      • Head warpage or cracking could result from removing bolts in the wrong order.

  37. REMOVE CYLINDER HEAD GASKET

  38. REMOVE OIL FILTER SUB-ASSEMBLY

    A005I85E03

    1. Using SST, remove the oil filter.

      SST
      09228-06501

  39. REMOVE OIL FILTER UNION

    A005KXO

    1. Using a 12 mm (0.47 in.) hexagon wrench, remove the oil filter union.

  40. REMOVE ENGINE REAR OIL SEAL

    A005GG7E07
    Text in Illustration
    *1 Protective Tape

    1. Using a knife, cut off the oil seal lip.

    2. Using a screwdriver with its tip wrapped in protective tape, pry out the oil seal.

      Note

      After removal, check the crankshaft for any damage. If damaged, smooth the surface with 400-grit sandpaper.

  41. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY


    1. Remove the oil pan drain plug and gasket.

    2. A005JVX

      Remove the 9 bolts and 2 nuts.

    3. A005HOE

      Insert the blade of oil pan seal cutter between the No. 1 oil pan and No. 2 oil pan, and cut off the applied sealer and remove No. 2 oil pan.

      Note

      Do not damage the No. 1 oil pan or No. 2 oil pan.

  42. REMOVE OIL STRAINER SUB-ASSEMBLY


    1. Remove the bolt and 2 nuts.

    2. Remove the oil strainer and the gasket.

  43. REMOVE OIL PAN SUB-ASSEMBLY

    A005J0V

    1. Loosen and remove the 13 bolts uniformly in several steps.

    2. A005LXP

      Using a screwdriver, remove the No. 1 oil pan by prying between the cylinder block and No. 1 oil pan.

      Note

      Do not damage the contact surfaces of the No. 1 oil pan or the cylinder block.

    3. Remove the 2 O-rings from the cylinder block.

  44. REMOVE STUD BOLT

    A005M1Q

    1. Remove the 4 stud bolts.