ENGINE UNIT DISASSEMBLY

PROCEDURE


  1. REMOVE NO. 1 FUEL PIPE SUB-ASSEMBLY (for High Pressure)

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  2. REMOVE FUEL DELIVERY PIPE (for Port Injection)

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  3. REMOVE PORT FUEL INJECTOR ASSEMBLY (for Port Injection)

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  4. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY (for Direct Injection)

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  5. REMOVE DIRECT FUEL INJECTOR ASSEMBLY (for Direct Injection)

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  6. REMOVE FUEL INJECTOR SEAL (for Direct Injection)

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  7. REMOVE FUEL PUMP ASSEMBLY (for High Pressure)

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  8. REMOVE VACUUM PUMP ASSEMBLY

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  9. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE

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  10. REMOVE NO. 3 EXHAUST MANIFOLD HEAT INSULATOR

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  11. REMOVE NO. 4 EXHAUST MANIFOLD HEAT INSULATOR

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  12. REMOVE NO. 1 WATER BY-PASS PIPE

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  13. REMOVE NO. 4 WATER BY-PASS PIPE


    1. B007Y4E

      Slide the clip and disconnect the No. 4 water by-pass pipe from the oil cooler assembly.

    2. Remove the 2 nuts, bolt, No. 4 water by-pass pipe and gasket.

  14. REMOVE OIL PRESSURE SENDER GAUGE ASSEMBLY

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  15. REMOVE WATER INLET HOUSING

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  16. REMOVE THERMOSTAT (for Cylinder Block)

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  17. REMOVE SPARK PLUG

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  18. REMOVE KNOCK SENSOR

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  19. REMOVE ENGINE COOLANT TEMPERATURE SENSOR

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  20. REMOVE OIL PRESSURE SENDER GAGE ASSEMBLY

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  21. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY

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  22. REMOVE PCV VALVE SUB-ASSEMBLY

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  23. REMOVE NO. 1 PCV CASE


    1. B007Z6DC01
      *a Bolt
      *b Nut

      Remove the 6 bolts and 2 nuts.

    2. B00803H

      Remove the No. 1 PCV case by prying between the No. 1 PCV case and cylinder block sub-assembly with a screwdriver with its tip wrapped with protective tape at the places shown in the illustration.

      Note


      • Be careful not to damage the contact surfaces of the cylinder block sub-assembly.

      • Do not reuse the No. 1 PCV case.

  24. REMOVE CRANKSHAFT PULLEY ASSEMBLY


    1. B007Z8PC03
      *a Hold
      *b Turn

      Using SST, hold the crankshaft pulley assembly, loosen the crankshaft pulley set bolt until 2 or 3 threads remain screwed into the crankshaft.

      SST
      09213-54015
      09330-00021

      Tech Tips

      Part number of installation bolt for SST (crankshaft pulley holding tool): 91551-80650 (quantity: 2)

    2. B007ZYHC01
      *1 Crankshaft Pulley Set Bolt
      *a Hold
      *b Turn

      Using SST, remove the crankshaft pulley assembly and crankshaft pulley set bolt.

      SST
      09950-50013   ( 09951-05010, 09952-05010, 09953-05020, 09954-05011, 09957-04010 )

      Tech Tips

      Apply lubricant to the threads and end of SST.

  25. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY


    1. B007ZGSC01
      *1 Camshaft Position Sensor

      Remove the 2 bolts and 2 camshaft position sensors from the cylinder head cover sub-assembly.

    2. Remove the 19 bolts and cylinder head cover sub-assembly from the camshaft housing sub-assembly.

    3. B007X89C01
      *1 Cylinder Head Cover Gasket
      *2 No. 2 Cylinder Head Cover Gasket

      Remove the cylinder head cover gasket and No. 2 cylinder head cover gasket from the cylinder head cover sub-assembly.

    4. B007YC0

      Remove the 2 gaskets from the No. 1 camshaft bearing cap and No. 2 camshaft bearing cap.

  26. REMOVE PCV HOSE (w/o Canister Pump Module)


    1. B00803O

      Slide the clamp and remove the PCV hose from the cylinder head cover sub-assembly.

  27. REMOVE NO. 4 PCV HOSE (w/o Canister Pump Module)


    1. B007X8D

      Slide the clamp and remove the No. 4 PCV hose from the cylinder head cover sub-assembly.

  28. REMOVE SPARK PLUG TUBE GASKET


    1. B007Y98C01
      *a Protective Tape

      Using a screwdriver with its tip wrapped with protective tape, remove the 4 spark plug tube gaskets from the cylinder head cover sub-assembly.

      Note

      Be careful not to damage the cylinder head cover sub-assembly.

  29. REMOVE ENGINE MOUNTING BRACKET RH


    1. B007XOB

      Remove the 4 bolts and engine mounting bracket RH.

  30. REMOVE CAMSHAFT TIMING OIL CONTROL SOLENOID ASSEMBLY

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  31. REMOVE TIMING CHAIN COVER ASSEMBLY

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  32. REMOVE TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL


    1. B007ZK7C01
      *a Protective Tape
      *b Wooden Block

      Using a screwdriver and wooden block, pry out the timing gear case or timing chain case oil seal.

      Note

      Do not damage the surface of the timing gear case or timing chain case oil seal press fit hole.

      Tech Tips

      Tape the screwdriver tip before use.

  33. REMOVE TIMING CHAIN COVER PLATE


    1. B00802Y

      Remove the 4 bolts, timing chain cover plate and gasket.

  34. SET NO. 1 CYLINDER TO TDC/COMPRESSION


    1. Temporarily install the crankshaft pulley set bolt.

    2. Rotate the crankshaft clockwise and align the timing marks on the camshaft timing gear assembly, camshaft timing exhaust gear assembly and crankshaft pulley set key of the crankshaft timing sprocket as shown in the illustration.

      B007ZOCC02
      *1 Crankshaft Pulley Set Key - -
      *a Approximately 7° *b Approximately 32°
      *c Timing Mark - -

      Tech Tips

      If the timing marks are not aligned, rotate the crankshaft clockwise again and align the timing marks.

    3. Remove the crankshaft pulley set bolt.

  35. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY


    1. B007ZKAC02
      *a Stopper Plate
      *b Plunger

      Allow the plunger to extend slightly, and then rotate the stopper plate counterclockwise to release the lock. Once the lock is released, push the plunger into the No. 1 chain tensioner assembly.

    2. B007ZBUC02
      *a Pin

      Rotate the stopper plate clockwise to set the lock, and then insert a pin into the stopper plate hole.

    3. B007WOL

      Remove the nut, bolt, No. 1 chain tensioner assembly and gasket.

  36. REMOVE TIMING CHAIN GUIDE


    1. B007Y4G

      Remove the bolt and timing chain guide.

  37. REMOVE CHAIN TENSIONER SLIPPER


    1. B007ZY5

      Remove the bolt and chain tensioner slipper.

  38. REMOVE CHAIN SUB-ASSEMBLY


    1. Remove the chain sub-assembly.

  39. REMOVE NO. 1 CHAIN VIBRATION DAMPER


    1. B007WLR

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

  40. REMOVE CRANKSHAFT TIMING SPROCKET


    1. B007X9R

      Remove the crankshaft timing sprocket from the crankshaft.

  41. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY


    1. B007Y7QC03
      *a Hold
      *b Turn

      Using a wrench to hold the hexagonal portion of the camshaft, remove the camshaft timing gear bolt and camshaft timing gear assembly.

      Note


      • Be careful not to damage the camshaft housing sub-assembly or spark plug tube with the wrench.

      • Do not disassemble the camshaft timing gear assembly.

  42. REMOVE CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY


    1. B007YTRC03
      *a Hold
      *b Turn

      Using a wrench to hold the hexagonal portion of the No. 2 camshaft, remove the bolt and camshaft timing exhaust gear assembly.

      Note


      • Be careful not to damage the camshaft housing sub-assembly or spark plug tube with the wrench.

      • Do not disassemble the camshaft timing exhaust gear assembly.

  43. REMOVE OIL PIPE SUB-ASSEMBLY


    1. B007ZT9

      Remove the bolt and oil pipe sub-assembly.

  44. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY


    1. B007X7EN04

      Uniformly loosen and remove the 22 bolts in the order shown in the illustration.

    2. B007XL2

      Remove the camshaft housing sub-assembly by prying between the cylinder head sub-assembly and camshaft housing sub-assembly with a screwdriver with its tip wrapped with protective tape at the places shown in the illustration.

      Note

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

  45. REMOVE NO. 3 WATER BY-PASS PIPE


    1. B007YETC01
      *1 No. 6 Water By-pass Hose

      Slide the clip and disconnect the No. 6 water by-pass hose from the cylinder head sub-assembly.

    2. Remove the 3 bolts, No. 3 water by-pass pipe and gasket.

  46. REMOVE CAMSHAFT BEARING CAP


    1. B007XWMN04

      Remove the 11 bolts in the order shown in the illustration.

    2. Remove the No. 1 camshaft bearing cap, No. 2 camshaft bearing cap, No. 3 camshaft bearing cap and No. 4 camshaft bearing cap.

      Tech Tips

      Arrange the removed parts in such a way that they can be reinstalled to their original locations.

  47. REMOVE OIL CONTROL VALVE FILTER


    1. B007WQH

      Remove the oil control valve filter from the No. 1 camshaft bearing cap.

  48. REMOVE CAMSHAFT


    1. Remove the camshaft from the camshaft housing sub-assembly.

  49. REMOVE NO. 2 CAMSHAFT


    1. Remove the No. 2 camshaft from the camshaft housing sub-assembly.

  50. REMOVE NO. 1 CAMSHAFT BEARING


    1. B007XN0

      Remove the No. 1 camshaft bearing from the No. 1 camshaft bearing cap.

  51. REMOVE NO. 2 CAMSHAFT BEARING


    1. B007Z34

      Remove the No. 2 camshaft bearing from the camshaft housing sub-assembly.

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


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

      Tech Tips

      Arrange the removed parts in such a way that they can be reinstalled to their original locations.

  53. REMOVE VALVE LASH ADJUSTER ASSEMBLY


    1. Remove the 16 valve lash adjuster assemblies.

      Tech Tips

      Arrange the removed parts in such a way that they can be reinstalled to their original locations.

  54. REMOVE VALVE STEM CAP


    1. Remove the 16 valve stem caps.

      Tech Tips

      Arrange the removed parts in such a way that they can be reinstalled to their original locations.

  55. REMOVE CYLINDER HEAD SUB-ASSEMBLY

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  56. REMOVE CYLINDER HEAD GASKET

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  57. REMOVE CYLINDER BLOCK WATER JACKET SPACER


    1. B007Y9Z

      Remove the cylinder block water jacket spacer from the cylinder block sub-assembly.

      Note

      Be sure to remove the cylinder block water jacket spacer. If it is not removed, it may fall and become damaged when the cylinder block sub-assembly is inverted.

  58. REMOVE OIL FILTER CAP ASSEMBLY

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  59. REMOVE OIL FILTER BRACKET CLIP


    1. B007XP3

      Remove the oil filter bracket clip from the stiffening crankcase assembly.

  60. REMOVE OIL COOLER ASSEMBLY


  61. REMOVE OIL PAN DRAIN PLUG


    1. Remove the oil pan drain plug and gasket from the oil pan sub-assembly.

  62. REMOVE OIL PAN SUB-ASSEMBLY


    1. w/o Canister Pump Module:


      1. B007ZEO

        Remove the 11 bolts and 2 nuts.

    2. w/ Canister Pump Module:


      1. B007XMA

        Remove the 11 bolts and 2 nuts.

    3. B007X3E

      Insert the blade of an oil pan seal cutter between the oil pan sub-assembly and stiffening crankcase assembly, cut through the applied sealer and remove the oil pan sub-assembly.

      Note


      • Be careful not to damage the contact surfaces of the stiffening crankcase assembly and oil pan sub-assembly.

      • Be careful not to damage the stiffening crankcase assembly flange.

  63. REMOVE ENGINE OIL LEVEL SENSOR

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  64. REMOVE OIL STRAINER SUB-ASSEMBLY


    1. B007ZUP

      Remove the 3 bolts, oil strainer sub-assembly and gasket.

  65. REMOVE NO. 1 OIL PAN BAFFLE PLATE


    1. B007ZAB

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

  66. INSPECT ENGINE BALANCER ASSEMBLY BACKLASH


    1. B007YY9

      Using a dial indicator, measure the backlash of the crankshaft and balance shaft as shown in the illustration.

      Standard Backlash
      0.05 to 0.20 mm (0.00197 to 0.00787 in.)
      Maximum Backlash
      0.20 mm (0.00787 in.)

      If the backlash is more than the maximum, replace the engine balancer assembly.

  67. REMOVE ENGINE BALANCER ASSEMBLY


    1. B007Y3S

      Remove the 7 bolts and engine balancer assembly.

      Note

      Do not disassemble the engine balancer assembly.

  68. REMOVE ENGINE OIL TEMPERATURE SENSOR

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  69. REMOVE STIFFENING CRANKCASE ASSEMBLY


    1. w/o Canister Pump Module:


      1. B007XD7

        Remove the 8 bolts.

      2. B007YNS

        Using a screwdriver with its tip wrapped with protective tape, remove the stiffening crankcase assembly by prying between the stiffening crankcase assembly and cylinder block sub-assembly at the places shown in the illustration.

        Note

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

    2. w/ Canister Pump Module:


      1. B007ZA9

        Remove the 8 bolts.

      2. B007ZZY

        Using a screwdriver with its tip wrapped with protective tape, remove the stiffening crankcase assembly by prying between the stiffening crankcase assembly and cylinder block sub-assembly at the places shown in the illustration.

        Note

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

  70. REMOVE REAR ENGINE OIL SEAL


    1. Remove the rear engine oil seal from the cylinder block sub-assembly.

  71. REMOVE STUD BOLT

    Note

    If a stud bolt is deformed or its threads are damaged, replace it.

  72. REMOVE RING PIN

    Note

    It is not necessary to remove the ring pin unless it is being replaced.