ENGINE UNIT DISASSEMBLY

PROCEDURE

  1. REMOVE OIL FILLER CAP SUB-ASSEMBLY

    1. A173599

      Remove the oil filler cap sub-assembly.

  2. REMOVE OIL FILLER CAP GASKET

    1. A128159

      Remove the oil filler cap gasket.

  3. REMOVE ENGINE COVER JOINT

    1. A150847

      Remove the 2 engine cover joints.

  4. REMOVE SPARK PLUG

    Click here

  5. REMOVE CAMSHAFT POSITION SENSOR

    1. for Intake Side:

      Click here

    2. for Exhaust Side:

      Click here

  6. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY

    1. for Intake Side:

      Click here

    2. for Exhaust Side:

      Click here

  7. REMOVE CRANKSHAFT POSITION SENSOR

    Click here

  8. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY

    Click here

  9. REMOVE KNOCK SENSOR

    Click here

  10. REMOVE ENGINE COOLANT TEMPERATURE SENSOR

    Click here

  11. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY

    1. A173472

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

    2. A165301

      Remove the 3 gaskets from the camshaft bearing cap.

      Note:

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

  12. REMOVE CYLINDER HEAD COVER GASKET

    1. A179166

      Remove the cylinder head cover gasket.

  13. REMOVE SPARK PLUG TUBE GASKET

    1. A179167

      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. A329121

      Using a screwdriver as shown in the illustration, deform each spark plug tube gasket inwards and remove the 4 spark plug tube gaskets from 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-grid sandpaper.

  14. REMOVE OIL FILTER

    Click here

  15. REMOVE UNION

    1. A366750

      for Oil Filter Sub-assembly Type:

      Using a 12 mm hexagon wrench, remove the union.

  16. SET NO. 1 CYLINDER TO TDC/COMPRESSION

    1. A282680C05

      *1

      Timing Mark

      *2

      Notch

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

      Tip:

      • A in the illustration is not the timing mark.

      • Do not align the timing mark with notch B on the crankshaft pulley in the illustration.

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

      Tip:

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

  17. REMOVE CRANKSHAFT PULLEY

    Click here

  18. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY

    1. A250765

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

      Note:

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

  19. REMOVE ENGINE MOUNTING BRACKET STUD BOLT

    1. A211980

      Remove the engine mounting bracket stud bolt.

  20. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY

    Click here

  21. REMOVE TIMING CHAIN COVER OIL SEAL

    Click here

  22. REMOVE WATER INLET HOUSING

    1. A150906

      Remove the 3 bolts, water inlet housing and gasket.

  23. REMOVE NO. 1 GENERATOR BRACKET

    1. A343666

      Remove the 4 bolts and No. 1 generator bracket.

  24. REMOVE CHAIN TENSIONER SLIPPER

    1. A173477

      Remove the chain tensioner slipper from the cylinder block assembly.

  25. REMOVE NO. 1 CHAIN VIBRATION DAMPER

    1. A165303

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

  26. REMOVE CHAIN SUB-ASSEMBLY

    1. A165304

      Hold the hexagonal portion of the camshaft with a wrench and turn the camshaft timing gear 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 and place it on the camshaft timing gear.

      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.

  27. REMOVE CRANKSHAFT TIMING SPROCKET

    Click here

  28. REMOVE NO. 2 CHAIN SUB-ASSEMBLY

    Click here

  29. REMOVE NO. 1 CRANKSHAFT POSITION SENSOR PLATE

    1. A150874

      Remove the No. 1 crankshaft position sensor plate.

  30. REMOVE CRANKSHAFT TIMING GEAR KEY

    1. A150909C07

      *1

      Protective Tape

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

      Tip:

      Tape the screwdriver tip before use.

  31. INSPECT CAMSHAFT TIMING GEAR ASSEMBLY

    Click here

  32. INSPECT CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY

    Click here

  33. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY

    Click here

  34. REMOVE CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY

    Click here

  35. REMOVE VALVE ROCKER ARM LOST MOTION DAMPER SUB-ASSEMBLY

    Click here

  36. INSTALL VALVE ROCKER ARM LOST MOTION DAMPER SUB-ASSEMBLY

    Click here

  37. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY

    Click here

  38. REMOVE CONTINUOUSLY VARIABLE VALVE LIFT CONTROLLER ASSEMBLY

    1. A173790

      Using a screwdriver, slide the control actuator clip from the control actuator connector.

      Note:

      Slide only the upper part of the control actuator clip, as the straight pin may fall if the control actuator clip is completely removed.

    2. A316504

      Using 2 screwdrivers, lightly pry the control actuator connector to make a space between the continuously variable valve lift controller assembly and camshaft housing sub-assembly.

      Note:

      • Do not forcefully pry the control actuator connector.

      • Do not damage the camshaft housing sub-assembly and camshaft bearing cap.

    3. A174269

      Using a magnet hand, remove the straight pin from the control actuator connector.

      Tip:

      The straight pin can be removed by utilizing the space between the continuously variable valve lift controller assembly and camshaft housing sub-assembly to move the continuously variable valve lift controller assembly so that there is no load on the straight pin.

    4. A317707C01

      *1

      Continuously Variable Valve Lift Controller Assembly

      *2

      O-Ring

      Remove the bolt and the continuously variable valve lift controller assembly from the camshaft housing sub-assembly.

    5. Remove the O-ring from the continuously variable valve lift controller assembly.

      Note:

      The O-ring may remain on the camshaft housing side. Be sure to always remove it.

    6. A320543

      Remove the valve lift control actuator connector from the valve rocker shaft.

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

    1. A332572

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

      Tip:

      Arrange the removed parts in the correct order.

  40. REMOVE VALVE LASH ADJUSTER ASSEMBLY

    1. A270930

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

      Tip:

      Arrange the removed parts in the correct order.

  41. REMOVE VALVE STEM CAP

    1. A329106

      Remove the 16 valve stem caps.

      Tip:

      Arrange the removed parts in the correct order.

  42. REMOVE CYLINDER HEAD SUB-ASSEMBLY

    Click here

  43. REMOVE CAMSHAFT HOUSING STRAIGHT PIN

    Note:

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

  44. REMOVE CYLINDER HEAD GASKET

    Click here

  45. REMOVE PCV VALVE SUB-ASSEMBLY

    Click here

  46. REMOVE OIL PAN DRAIN PLUG

    1. A150893

      Remove the oil pan drain plug and gasket.

  47. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY

    Click here

  48. REMOVE OIL PUMP ASSEMBLY

    Click here

  49. REMOVE ENGINE REAR OIL SEAL

    Click here

  50. REMOVE STIFFENING CRANKCASE ASSEMBLY

    1. A150897

      Uniformly loosen and remove the 11 bolts.

    2. A150898C07

      *1

      Protective Tape

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

      Note:

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

      Tip:

      Tape the screwdriver tip before use.

  51. REMOVE NO. 1 TAPER SCREW PLUG

    1. A300838

      Remove the No. 1 taper screw plug.

  52. REMOVE STUD BOLT

    Note:

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

  53. REMOVE STIFFENING CRANKCASE RING PIN

    Note:

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