ENGINE UNIT DISASSEMBLY

PROCEDURE

  1. REMOVE OIL FILLER CAP SUB-ASSEMBLY

    1. A150846

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

  2. REMOVE OIL FILLER CAP GASKET

    1. A128159

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

  3. REMOVE ENGINE COVER JOINT

    1. A150847

      Remove the 2 engine cover joints from the cylinder head cover sub-assembly.

  4. REMOVE SPARK PLUG

  5. REMOVE CAMSHAFT POSITION SENSOR

    1. A150848

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

  6. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY

    1. A150849

      Remove the 2 bolts, wire harness bracket and 2 camshaft timing oil control valve assemblies.

    2. Remove the 2 O-rings from the camshaft timing oil control valve assemblies.

  7. REMOVE CRANKSHAFT POSITION SENSOR

    1. A150855

      Remove the bolt and crankshaft position sensor.

  8. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY

    1. A150856

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

  9. REMOVE KNOCK CONTROL SENSOR

    1. A152587

      Remove the bolt and knock control sensor.

  10. REMOVE ENGINE COOLANT TEMPERATURE SENSOR

    1. A296220

      Remove the engine coolant temperature sensor.

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

  11. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY

    1. A150850

      Remove the 13 bolts, seal washer and cylinder head cover sub-assembly from the camshaft housing sub-assembly.

    2. A150852

      Remove the 3 gaskets from the camshaft bearing cap.

      Note:

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

  12. REMOVE CYLINDER HEAD COVER GASKET

    1. A296222

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

  13. REMOVE SPARK PLUG TUBE GASKET

    1. A152586

      Pry up the 4 claws of the ventilation baffle plate.

      Note:

      Do not deform the claws of the ventilation baffle plate more than necessary.

    2. A352625

      Using a screwdriver as shown in the illustration, deform each spark plug tube gasket inwards and remove the 4 spark plug tube gaskets from the cylinder head cover sub-assembly.

      Note:
      • As much as possible prevent the spark plug tube gaskets from being deformed.

        The removed spark plug tube gaskets will be used when reinstalling the new spark plug tube gaskets.

      • Do not damage the cylinder head cover sub-assembly.

      • Make sure not to damage the spark plug tube gasket and cylinder head cover sub-assembly when inserting the screwdriver in the joint area.

      Tip:
      • If the cylinder head cover sub-assembly is damaged, smooth the surface with 400-grit sandpaper.

      • Prevent the spark plug tube gaskets from being deformed as much as possible. The removed spark plug tube gaskets will be used when installing new spark plug tube gaskets.

      1. A297053C01

        *a

        Before cutting off

        *b

        After cutting off

        V100155

        Area to be cut off

        Using a cutter, cut off the sealing part of the removed plug tube gasket.

  14. REMOVE OIL FILTER CAP ASSEMBLY

  15. REMOVE WATER INLET HOUSING

    1. A150906

      Remove the 3 bolts, gasket and water inlet housing.

  16. SET NO. 1 CYLINDER TO TDC/COMPRESSION

    1. A404240C01

      *a

      Timing Mark

      *b

      Timing Notch

      Turn the crankshaft pulley until its timing notch and timing mark "0" of the timing chain cover sub-assembly are aligned.

    2. Check that timing marks on the camshaft timing exhaust gear assembly and camshaft timing gear assembly are facing upward as shown in the illustration.

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

  17. REMOVE CRANKSHAFT PULLEY

  18. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY

    1. A150854

      Remove the 2 nuts, bracket, No. 1 chain tensioner assembly and gasket.

      Note:

      Do not turn the crankshaft without the No. 1 chain tensioner assembly installed.

  19. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY

  20. REMOVE TIMING CHAIN COVER OIL SEAL

    1. A150869C04

      *a

      Wooden Block

      *b

      Protective Tape

      Using a screwdriver and hammer, remove the timing chain cover oil seal.

      Note:

      Be careful not to damage the timing chain cover sub-assembly.

      Tip:

      Tape the screwdriver tip before use.

  21. REMOVE NO. 1 GENERATOR BRACKET

    1. A150905

      Remove the 4 bolts and No. 1 generator bracket.

  22. REMOVE NO. 2 CHAIN VIBRATION DAMPER

    1. A153395

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

  23. REMOVE CHAIN TENSIONER SLIPPER

    1. A296232

      Remove the chain tensioner slipper.

  24. REMOVE NO. 1 CHAIN VIBRATION DAMPER

    1. A165280

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

  25. REMOVE CHAIN SUB-ASSEMBLY

    1. A152590C01

      *a

      Turn

      *b

      Place the Chain Sub-assembly on the Camshaft Timing Gear Assembly

      *c

      Loosen the Chain Sub-assembly

      Hold the hexagonal portion of the camshaft with a wrench and turn the camshaft timing gear assembly counterclockwise to loosen the chain sub-assembly between the camshaft timing gears.

    2. With the chain sub-assembly loosened, release the chain sub-assembly from the camshaft timing gear assembly and place it on the camshaft timing gear assembly.

      Tip:

      Be sure to release the chain sub-assembly from the sprocket completely.

    3. Turn the camshaft clockwise to return it to the original position and remove the chain sub-assembly.

  26. REMOVE CRANKSHAFT TIMING SPROCKET

  27. REMOVE NO. 2 CHAIN SUB-ASSEMBLY

  28. REMOVE NO. 1 CRANKSHAFT POSITION SENSOR PLATE

    1. A150874

      Remove the No. 1 crankshaft position sensor plate.

  29. REMOVE CRANKSHAFT TIMING GEAR KEY

    1. A150909C11

      *a

      Protective Tape

      Using a screwdriver, remove the 2 crankshaft timing gear keys.

      Tip:

      Tape the screwdriver tip before use.

  30. REMOVE NO. 1 TAPER SCREW PLUG

    1. A235913

      Remove the 2 No. 1 taper screw plugs.

  31. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY

    1. Check the lock of the camshaft timing gear assembly.

    2. Release the lock pin.

      Note:

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

      1. A173366C02

        *a

        Adhesive Tape Sealing Area

        *b

        Prick a Hole

        *c

        Adhesive Tape

        After cleaning 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. A173367

        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.

        Tip:
        • Depending on the air pressure applied, the camshaft timing gear assembly may turn in the advance direction without assistance by hand.

        • 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. A162976C02

      *1

      Bolt

      *a

      Do not remove

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

      Note:
      • Do not remove the other 4 bolts.

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

  32. REMOVE CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY

    1. A162977C01

      *1

      Bolt

      *a

      Do not remove

      Remove the bolt while holding the hexagonal portion of the No. 2 camshaft, then remove the camshaft timing exhaust gear assembly.

      Note:
      • Do not remove the other 4 bolts.

      • Keep the camshaft timing exhaust gear assembly horizontal while removing it from the No. 2 camshaft.

  33. REMOVE CAMSHAFT BEARING CAP

    1. A153396N03

      Uniformly loosen and remove the 10 bearing cap bolts in the order shown in the illustration.

    2. A153398N02

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

      Note:

      Uniformly loosen the bolts while keeping the camshaft level.

    3. Remove the 5 camshaft bearing caps.

      Tip:

      Arrange the removed parts in the correct order.

  34. REMOVE CAMSHAFT

    1. A152662

      Remove the camshaft.

  35. REMOVE NO. 2 CAMSHAFT

    1. A152663

      Remove the No. 2 camshaft.

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

    1. A296227

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

      Tip:

      Arrange the removed parts in the correct order.

  37. REMOVE VALVE LASH ADJUSTER ASSEMBLY

    1. A296230

      Remove the 16 valve lash adjuster assemblies from the cylinder head sub-assembly.

      Tip:

      Arrange the removed parts in the correct order.

  38. REMOVE OIL CONTROL VALVE FILTER

    1. A150883

      Remove the oil control valve filter.

  39. REMOVE NO. 1 CAMSHAFT BEARING

  40. REMOVE NO. 2 CAMSHAFT BEARING

    1. A296229

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

      Note:

      Arrange the removed parts in the correct order.

  41. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY

    1. A150889

      Remove the 2 bolts.

    2. A150888C06

      *a

      Protective Tape

      Remove the camshaft housing sub-assembly by prying between the cylinder head sub-assembly and camshaft housing sub-assembly with a screwdriver.

      Note:

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

      Tip:

      Tape the screwdriver tip before use.

  42. REMOVE CYLINDER HEAD SUB-ASSEMBLY

  43. REMOVE CYLINDER HEAD GASKET

  44. REMOVE PCV VALVE (VENTILATION VALVE SUB-ASSEMBLY)

  45. REMOVE OIL PAN DRAIN PLUG

    1. A150893

      Remove the oil pan drain plug and gasket.

  46. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY

  47. REMOVE OIL PUMP ASSEMBLY

  48. REMOVE REAR ENGINE OIL SEAL

  49. REMOVE STIFFENING CRANKCASE ASSEMBLY

    1. A150897

      Uniformly loosen and remove the 11 bolts.

    2. A150898C05

      *a

      Protective Tape

      Using a screwdriver, remove the stiffening crankcase assembly by prying between the stiffening crankcase and cylinder block sub-assembly.

      Note:

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

      Tip:

      Tape the screwdriver tip before use.

  50. REMOVE RING PIN

    Note:

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

    1. A296589

      Remove the 2 ring pins from the stiffening crankcase assembly.

  51. REMOVE STUD BOLT

    Note:

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

    1. A296590

      for Stiffening crankcase assembly:

      1. Using an E5 "TORX" socket wrench, remove the 2 stud bolts from the stiffening crankcase assembly.

    2. A296591

      for Water inlet housing:

      1. Using an E5 "TORX" socket wrench, remove the 2 stud bolts from the water inlet housing.