ENGINE UNIT DISASSEMBLY

PROCEDURE

  1. REMOVE SPARK PLUG

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  2. REMOVE OIL FILLER CAP SUB-ASSEMBLY

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

  3. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY

    1. A349644

      Remove the 17 bolts and cylinder head cover sub-assembly.

  4. REMOVE CYLINDER HEAD COVER GASKET

    1. A325789C01

      *1

      Cylinder Head Cover Gasket

      Remove the 2 cylinder head cover gaskets.

  5. REMOVE STUD BOLT

    Tip:

    Perform this procedure only when replacement of the stud bolt is necessary.

    1. A319024

      Using an E10 "TORX" socket wrench, remove the 2 stud bolts from the cylinder head sub-assembly.

  6. CHECK CAMSHAFT TIMING GEAR ASSEMBLY

    1. Turn the crank pulley 2 revolutions.

    2. A319010

      Using a wrench, slowly turn the camshaft left and right and check that the camshaft timing gear assembly and camshaft turn together.

      A319022
      Tip:

      If the camshaft timing gear assembly and camshaft do not turn together, turn the camshaft up to 35° counterclockwise.

  7. CHECK CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY

    1. A319011

      Using a wrench, slowly turn the No. 2 camshaft left and right and check that the camshaft timing exhaust gear assembly and No. 2 camshaft turn together.

      A319023
      Tip:

      If the camshaft timing exhaust gear assembly and No. 2 camshaft do not turn together, turn the No. 2 camshaft up to 35° clockwise.

  8. REMOVE CRANKSHAFT PULLEY

    1. Lock the crankshaft.

      1. A319012C01

        *a

        Flat Portion (A)

        Turn the crankshaft clockwise so that the flat portion (A) of the camshaft and No. 2 camshaft are positioned as shown in the illustration.

      2. A319013N01

        Turn the crankshaft clockwise and install SST as shown in the illustration.

        0109-2

        0109-2B

      3. Confirm that the crankshaft is locked and cannot be turned.

    2. Lock the camshaft.

      1. A319014C01

        *a

        Flat Portion (A)

        *b

        Cylinder Head Cover Sub-assembly Bolt

        *c

        SST Bolt

        Place SST on the cylinder head sub-assembly.

        0109-2

        0109-2A

        Tip:

        • Check that the flat portion (A) of the camshaft and No. 2 camshaft are positioned as shown in the illustration.

        • Check that SST is securely installed to the flat portion (A) of the camshaft and No. 2 camshaft.

        • Check that there is no gap between SST and the cylinder head sub-assembly.

      2. Using 2 cylinder head cover sub-assembly bolts, secure SST.

      3. Using a hexagon wrench, tighten the SST bolt.

    3. A338055

      Remove the 3 bolts and crankshaft pulley.

  9. REMOVE CRANKSHAFT PULLEY HUB OIL SEAL

    1. A338056

      Using a screwdriver with its tip wrapped with protective tape, pry out the crankshaft pulley hub oil seal.

  10. REMOVE CYLINDER BLOCK COVER

    1. A338057

      Remove the 4 bolts and cylinder block cover.

    2. A325793C01

      *1

      Cylinder Block Cover Gasket

      Remove the cylinder block cover gasket.

  11. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Intake Side)

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  12. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Exhaust Side)

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  13. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE

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  14. REMOVE NO. 1 WATER BY-PASS PIPE

    1. A325794

      Remove the bolt and No. 1 water by-pass pipe.

  15. REMOVE FUEL DELIVERY PIPE

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  16. REMOVE TIMING BELT TENSIONER ASSEMBLY

    1. A325795

      Remove the bolt and timing belt tensioner assembly.

  17. REMOVE NO. 1 TIMING BELT IDLER SUB-ASSEMBLY

    1. A325796

      Remove the bolt and No. 1 timing belt idler sub-assembly.

  18. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY

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  19. REMOVE CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY

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  20. REMOVE CAMSHAFT

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  21. REMOVE NO. 2 CAMSHAFT

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  22. REMOVE CRANKSHAFT PULLEY HUB

    1. A325797

      Remove the bolt and crankshaft pulley hub.

  23. REMOVE CRANKSHAFT TIMING PULLEY

    1. A325798

      Remove the crankshaft timing pulley.

  24. REMOVE TIMING BELT

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  25. REMOVE ENGINE SPEED SENSOR PROTECTOR

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  26. REMOVE SPEED SENSOR

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  27. REMOVE FLYWHEEL SUB-ASSEMBLY

    1. A325800

      Remove the 6 bolts and flywheel sub-assembly.

  28. REMOVE NO. 1 FLYWHEEL SPACER

    1. A325801

      Remove the No. 1 flywheel spacer.

  29. REMOVE REAR CYLINDER BLOCK COVER

    1. A325802

      Remove the 8 bolts and rear cylinder block cover.

  30. REMOVE CAM POSITION SENSOR (for Exhaust Side)

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  31. REMOVE CAM POSITION SENSOR (for Intake Side)

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  32. REMOVE ENGINE COOLANT TEMPERATURE SENSOR

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  33. REMOVE KNOCK CONTROL SENSOR

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  34. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY

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  35. REMOVE ENGINE WATER HOUSING COVER

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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 PAN DRAIN PLUG

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

  39. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY

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  40. REMOVE OIL FILTER SUB-ASSEMBLY

    1. A325803

      Using SST, remove the oil filter sub-assembly from the oil pan sub-assembly.

      G-1404

  41. REMOVE OIL PAN SUB-ASSEMBLY

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  42. REMOVE NO. 1 OIL PAN BAFFLE PLATE

    1. A325806

      Remove the No. 1 oil pan baffle plate.

  43. REMOVE OIL PUMP ASSEMBLY

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  44. REMOVE ENGINE WATER PUMP ASSEMBLY

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