ENGINE UNIT DISASSEMBLY

PROCEDURE


  1. REMOVE SPARK PLUG

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  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 engine oil pressure switch assembly.

  4. REMOVE ENGINE COOLANT TEMPERATURE SENSOR

    A005HNV

    1. Using a 19 mm (0.748 in.) deep socket wrench, remove the engine coolant temperature sensor.

  5. REMOVE INLET WATER

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  6. REMOVE THERMOSTAT

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  7. REMOVE OIL FILLER CAP SUB-ASSEMBLY

    A005KFK

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

  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 oil filler cap gasket from the oil filler cap sub-assembly.

  9. REMOVE CRANKSHAFT POSITION SENSOR


    1. Remove the bolt and the crankshaft position sensor.

  10. REMOVE VENTILATION VALVE SUB-ASSEMBLY

    A005K69

    1. Remove the ventilation valve sub-assembly from the cylinder head cover sub-assembly.

  11. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY

    A005K2U

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

      Text in Illustration
      A005GO2 Bolt
      A005IBX Nut

  12. REMOVE CYLINDER HEAD COVER GASKET


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

  13. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY

    A005HOR

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

  14. REMOVE WATER PUMP PULLEY

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  15. REMOVE CRANKSHAFT DAMPER SUB-ASSEMBLY

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  16. REMOVE TRANSVERSE ENGINE ENGINE MOUNTING BRACKET

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  17. REMOVE ENGINE WATER PUMP ASSEMBLY

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  18. REMOVE OIL PUMP ASSEMBLY

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  19. REMOVE OIL PUMP SEAL

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  20. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY

    A005IRSE02
    Text in Illustration
    *1 Oil jet
    *a Timing Mark

    Note


    • Do not rotate the crankshaft with the No. 1 chain tensioner assembly removed.

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


    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 3.5 mm (0.14 in.) diameter bar into the hole in the stopper plate and lock the plunger.

    5. A005LWB

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

  23. REMOVE CHAIN SUB-ASSEMBLY


    1. Remove the chain sub-assembly.

  24. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY

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  25. REMOVE NO. 1 DELIVERY PIPE SPACER

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  26. REMOVE INJECTOR VIBRATION INSULATOR

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  27. REMOVE FUEL INJECTOR ASSEMBLY

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  28. REMOVE CAMSHAFT POSITION SENSOR

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  29. REMOVE NO. 2 CAMSHAFT

    A005I85E04

    Note

    Do not rotate the crankshaft with the No. 1 chain tensioner removed. When rotating the camshaft with the chain sub-assembly 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.

    Text in Illustration
    *1 Oil jet
    *a Timing Mark (1 dot)

    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 No. 2 camshaft in a vise.

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

      Note

      Do not damage the No. 2 camshaft.

  31. REMOVE CAMSHAFT

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  32. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY

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

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  34. REMOVE VALVE LASH ADJUSTER ASSEMBLY

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  35. REMOVE VALVE STEM CAP

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  36. REMOVE CYLINDER HEAD SUB-ASSEMBLY

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  37. REMOVE CYLINDER HEAD GASKET

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  38. REMOVE OIL FILTER SUB-ASSEMBLY

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  39. REMOVE OIL FILTER UNION

    A005KXO

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

  40. REMOVE REAR ENGINE OIL SEAL

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  41. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY


    1. A005M3JE01
      Text in Illustration
      *1 Oil Pan Drain Plug

      Remove the oil pan drain plug and gasket.

    2. Remove the 9 bolts and 2 nuts.

      Text in Illustration
      A005GO2 Bolt
      A005IBX Nut
    3. A005KMI

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

      Note

      Do not damage the oil pan sub-assembly or No. 2 oil pan sub-assembly.

  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 oil pan sub-assembly by prying between the cylinder block and oil pan sub-assembly.

      Note

      Do not damage the contact surfaces of the oil pan sub-assembly or the cylinder block.

    3. A005GY0

      Remove the 2 O-rings from the cylinder block.

  44. REMOVE STUD BOLT

    A005M1Q

    1. Remove the 4 stud bolts.