ENGINE UNIT DISASSEMBLY

PROCEDURE


  1. REMOVE REAR ENGINE OIL SEAL (w/o Stop and Start System)


    1. A005JRQE02
      Text in Illustration
      *1 Protective Tape
      *a Cut Position

      Using a knife, cut off the oil seal lip.

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

  2. REMOVE REAR ENGINE OIL SEAL (w/ Stop and Start System)


    1. A005GHAE02
      Text in Illustration
      *1 Protective Tape

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

      Note


      • If the snap ring is broken, the ring gear may move out from its original position and result in an oil leak. Therefore, it is necessary to confirm that the snap ring is installed correctly and undamaged when replacing the oil seal.

      • Be careful not to damage the crankshaft bearing.

  3. REMOVE CRANKSHAFT BEARING (w/ Stop and Start System)


    1. A005KSHE05

      Using SST, hold the crankshaft.

      SST
      09960-10010   ( 09962-01000, 09963-01000 )
    2. A005K5RE04
      Text in Illustration
      *a Turn
      *b Hold

      Using SST, remove the crankshaft bearing from the crankshaft.

      SST
      09950-40011   ( 09951-04010, 09952-04010, 09953-04020, 09954-04010, 09955-04071, 09957-04010, 09958-04011 )
      09950-60010   ( 09951-00280, 09951-00380, 09952-06010 )

    3. Remove the snap ring from the bearing.

  4. REMOVE OIL FILLER CAP SUB-ASSEMBLY


    1. A005MBB

      Remove the oil filler cap.

  5. REMOVE OIL FILLER CAP GASKET


    1. A005GGF

      Remove the gasket from the oil filler cap.

  6. REMOVE SPARK PLUG


    1. A005JML

      Using a 14 mm spark plug wrench, remove the 4 spark plugs.

  7. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY


    1. A005K10

      Remove the 2 bolts, 2 O-rings and 2 camshaft timing oil control valve assemblies.

  8. REMOVE NO. 1 CRANKSHAFT POSITION SENSOR


    1. A005JEW

      Remove the 2 bolts and 2 No. 1 crankshaft position sensors.

  9. REMOVE VENTILATION VALVE SUB-ASSEMBLY


    1. A005H0T

      Remove the ventilation valve sub-assembly.

  10. REMOVE VENTILATION SYSTEM GROMMET


    1. A005HA6

      Remove the ventilation system grommet from the cylinder head cover.

  11. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A005LGZ

      Remove the 17 bolts, seal washer and cylinder head cover.

      Note

      Be careful not to drop any of the gaskets into the engine when removing the cylinder head cover because the gaskets may stick to the cylinder head cover.

    2. A005JNZ

      Remove the cylinder head cover gasket.

    3. A005KWP

      Remove the 2 camshaft bearing cap oil hole gaskets from the camshaft bearing cap.

  12. REMOVE CRANKSHAFT POSITION SENSOR


    1. A005GGG

      Remove the bolt and crankshaft position sensor.

  13. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY


    1. A005JDM

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

  14. REMOVE KNOCK SENSOR


    1. A005L2O

      Remove the bolt and knock sensor.

  15. REMOVE ENGINE COOLANT TEMPERATURE SENSOR


    1. A005MFQ

      Remove the engine coolant temperature sensor.

    2. Remove the gasket from the engine coolant temperature sensor.

  16. REMOVE OIL FILTER ELEMENT

    Click here

  17. REMOVE WATER INLET

    Click here

  18. REMOVE NO. 2 WATER INLET HOUSING GASKET

    Click here

  19. REMOVE THERMOSTAT

    Click here

  20. SET NO. 1 CYLINDER TO TDC/COMPRESSION


    1. Turn the crankshaft pulley until its groove and the groove of the timing chain cover are aligned.

      A005IFVE02
      Text in Illustration
      *1 Timing Mark
      *a Groove

    2. Check that each timing mark of the camshaft timing gear and sprocket are located as shown in the illustration. If not, turn the crankshaft 1 revolution (360°) to align the timing marks as shown in the illustration.

  21. REMOVE CRANKSHAFT PULLEY


    1. A005GMWE10
      Text in Illustration
      *a Loosen
      *b Hold

      Using SST, remove the crankshaft pulley bolt.

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

    2. Remove the crankshaft pulley from the crankshaft.

  22. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY


    1. A005HLC

      Remove the 9 bolts and engine water pump assembly from the timing chain cover.

    2. A005GJ4

      Remove the 3 bolts and engine mounting bracket RH.

    3. A005JE0

      Remove the 21 bolts.

    4. A005MBLE02
      Text in Illustration
      *1 Protective Tape

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

      Note

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

    5. A005IFR

      Remove the 2 O-rings.

    6. A005HB5

      Using an 8 mm socket hexagon wrench, remove the plug.

  23. REMOVE TIMING CHAIN COVER OIL SEAL


    1. A005JZ0E01
      Text in Illustration
      *1 Protective Tape
      *2 Wooden Block

      Using a screwdriver with its tip wrapped with protective tape, remove the timing chain cover oil seal.

  24. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY


    1. A005M8NE01
      Text in Illustration
      *1 Timing Mark

      Set the camshaft timing gear, camshaft timing exhaust gear and crankshaft in the positions (20° ATDC) shown in the illustration.

    2. A005JK1E05
      Text in Illustration
      *1 Stopper Plate
      *2 Plunger
      *a Push

      Push down on the stopper plate to release the lock and push in the plunger.

    3. A005MIRE02
      Text in Illustration
      *1 Stopper Plate

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

    4. A005LPIE02
      Text in Illustration
      *1 Bar

      Insert a 3 mm (0.118 in.) diameter bar into the hole in the stopper plate and lock the plunger.

    5. A005I11

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

    6. A005HST

      Remove the gasket from the cylinder head.

  25. REMOVE NO. 2 CHAIN VIBRATION DAMPER


    1. A005JIQ

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

  26. REMOVE TIMING CHAIN TENSION ARM


    1. A005HRA

      Remove the bolt and timing chain tension arm.

  27. REMOVE CHAIN SUB-ASSEMBLY


    1. Remove the chain sub-assembly.

  28. REMOVE TIMING CHAIN GUIDE


    1. A005GTU

      Remove the 2 bolts and timing chain guide.

  29. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY


    1. A005M84E07

      Check the lock of the camshaft timing gear.

    2. Release the lock pin.

      Note

      Before removing the camshaft timing gear assembly, make sure that the lock pin has been released.


      1. After cleaning and degrease the VVT oil hole on the intake side of the No. 1 camshaft bearing cap, completely seal the oil hole with adhesive tape or equivalent as shown in the illustration to prevent air from leaking.

        Note

        Be sure to cover the oil hole completely because air leaks due to insufficient sealing will prevent the lock pin from being released.

      2. Prick a hole in the tape covering the oil hole as shown in the illustration (Procedure A).

      3. A005KN8
        Text in Illustration
        *1 Adhesive Tape
        *a Adhesive Tape Sealing Area
        *b Prick a Hole

        Apply approximately 150 kPa (1.5 kgf/cm2, 22 psi) of air pressure to the hole pricked in procedure A to release the lock pin.

        Note


        • If air leaks out, reattach adhesive tape.

        • Cover the oil hole with a piece of cloth when applying air pressure to prevent oil from spraying.

        • Do not lock the camshaft timing gear assembly. If it is locked, release the lock pin again.

        Tech Tips


        • The camshaft timing gear assembly may be turned in the advance direction without applying any force.

        • If enough air pressure cannot be applied because of air leakage from the port, releasing the lock pin may be difficult.

      4. Remove the adhesive tape from the No. 1 camshaft bearing cap.

    3. A005IUUE05
      Text in Illustration
      *a Do Not Remove

      Remove the flange bolt while holding the hexagonal portion of the camshaft, and then remove the camshaft timing gear assembly.

      Note


      • Before removing the camshaft timing gear, make sure that the lock pin has been released.

      • Be sure not to remove the other 4 bolts.

      • Keep the camshaft timing gear assembly horizontal while removing it from the camshaft.

  30. REMOVE CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY


    1. A005IKOE06
      Text in Illustration
      *a Do Not Remove

      Remove the flange bolt while holding the hexagonal portion of the camshaft, and then remove the camshaft timing exhaust gear assembly.

      Note


      • Be sure not to remove the other 4 bolts.

      • Keep the camshaft timing exhaust gear assembly horizontal while removing it from the camshaft.

  31. REMOVE CAMSHAFT BEARING CAP


    1. A005M29E02

      Uniformly loosen and remove the 5 bearing cap bolts in the sequence shown in the illustration.

    2. A005MBRE02

      Uniformly loosen and remove the 15 bearing cap bolts in the sequence shown in the illustration.

      Note

      Uniformly loosen the bolts while keeping the camshaft level.

    3. Remove the 5 bearing caps.

      Tech Tips

      Arrange the removed parts in the correct order.

  32. REMOVE NO. 2 CAMSHAFT


    1. A005KN0

      Remove the No. 2 camshaft.

  33. REMOVE CAMSHAFT


    1. A005KD4

      Remove the camshaft.

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

    A005KXSE01

    Tech Tips

    Type A and Type B can be distinguished by the shape of the compression spring.

    Type Compression Spring Shape
    A Straight
    B Taper
    *A Type A
    *B Type B
    *1 No. 1 Valve Rocker Arm Sub-assembly
    *2 Valve Spring Retainer
    *3 Compression Spring
    *4 Valve Lash Adjuster Assembly

    1. Type A and Type B:


      1. A005HO5

        Remove the 16 No. 1 valve rocker arm sub-assemblies.

        Tech Tips

        Arrange the removed parts in the correct order.

  35. REMOVE VALVE LASH ADJUSTER ASSEMBLY

    A005KXSE01

    Tech Tips

    Type A and Type B can be distinguished by the shape of the compression spring.

    Type Compression Spring Shape
    A Straight
    B Taper
    *A Type A
    *B Type B
    *1 No. 1 Valve Rocker Arm Sub-assembly
    *2 Valve Spring Retainer
    *3 Compression Spring
    *4 Valve Lash Adjuster Assembly

    1. Type A and Type B:


      1. A005LCI

        Remove the 16 valve lash adjuster assemblies from the cylinder head.

        Tech Tips

        Arrange the removed parts in the correct order.

  36. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY


    1. A005H00

      Remove the 3 bolts.

    2. A005LEJE05
      Text in Illustration
      *1 Protective Tape

      Using a screwdriver with its tip wrapped with protective tape, remove the camshaft housing by prying between the cylinder head and camshaft housing.

      Note

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

  37. REMOVE CYLINDER HEAD SUB-ASSEMBLY


    1. A005LQRE03

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

      Note

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

    2. Using a screwdriver with its tip wrapped with protective tape, pry between the cylinder head and cylinder block, and remove the cylinder head.

      Note

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

  38. REMOVE CYLINDER HEAD GASKET


    1. A005KAY

      Remove the cylinder head gasket.

  39. REMOVE CYLINDER BLOCK WATER JACKET SPACER


    1. A005JDI

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

  40. REMOVE OIL PAN DRAIN PLUG


    1. A005H1V

      Remove the oil pan drain plug and gasket from the oil pan.

  41. REMOVE OIL PAN SUB-ASSEMBLY


    1. A005JIA

      Uniformly loosen and remove the 10 bolts.

    2. A005I3TE02
      Text in Illustration
      *1 Protective Tape

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

      Note

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

    3. A005I42

      Remove the gasket from the cylinder block.

  42. REMOVE NO. 1 OIL PAN BAFFLE PLATE


    1. A005IH9

      Remove the 5 bolts and No. 1 oil pan baffle plate from the oil pan.

  43. REMOVE OIL STRAINER SUB-ASSEMBLY


    1. A005HS9

      Remove the 2 bolts and oil strainer sub-assembly from the oil pan.