ENGINE UNIT DISASSEMBLY

PROCEDURE

  1. REMOVE OIL FILLER CAP SUB-ASSEMBLY

    1. A197582

      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 SPARK PLUG

    Click here

  4. REMOVE NO. 1 CRANK POSITION SENSOR

    1. A197585

      Remove the 2 bolts and 2 No. 1 crank position sensors from the cylinder head cover sub-assembly.

  5. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY

    1. A197586

      Remove the 2 bolts and 2 camshaft timing oil control valve assemblies from the cylinder head cover sub-assembly.

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

  6. REMOVE VENTILATION VALVE SUB-ASSEMBLY

    1. A197587

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

  7. REMOVE VENTILATION SYSTEM GROMMET

    1. A197588

      Remove the ventilation system grommet from the cylinder head cover sub-assembly.

  8. REMOVE REAR ENGINE OIL SEAL

    Click here

  9. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY

    1. A256597C01

      *1

      Seal Washer

      Remove the 17 bolts, 2 seal washers and cylinder head cover sub-assembly.

      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.

    2. A197591

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

    3. A325197

      Remove the 2 camshaft bearing cap oil hole gaskets from the camshaft bearing cap.

      Note:

      If any camshaft bearing cap oil hole gasket is missing, check that no camshaft bearing cap oil hole gaskets are stuck to the cylinder head cover sub-assembly.

  10. REMOVE CRANK POSITION SENSOR

    1. A197599

      Remove the bolt and crank position sensor.

  11. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY

    1. A197595

      Using a 24 mm deep socket wrench, remove the engine oil pressure switch assembly from the cylinder block sub-assembly.

  12. REMOVE KNOCK CONTROL SENSOR

    1. A197596

      Remove the bolt and knock control sensor from the cylinder block sub-assembly.

  13. REMOVE ENGINE COOLANT TEMPERATURE SENSOR

    1. A197598

      Using a 19 mm deep socket wrench, remove the engine coolant temperature sensor from the cylinder head sub-assembly.

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

  14. REMOVE OIL FILTER ELEMENT

    Click here

  15. REMOVE WATER INLET

    Click here

  16. REMOVE NO. 2 WATER INLET HOUSING GASKET

    Click here

  17. REMOVE THERMOSTAT

    Click here

  18. SET NO. 1 CYLINDER TO TDC/COMPRESSION

    1. Turn the crankshaft until its groove and the groove of the timing chain cover sub-assembly are aligned.

      A287680C01

      *a

      Timing Mark

      *b

      Groove

    2. Check that each timing mark of the camshaft timing gear assembly and camshaft timing exhaust gear assembly are positioned as shown in the illustration. If not, turn the crankshaft 1 revolution (360°) to align the timing marks as shown in the illustration.

  19. REMOVE CRANKSHAFT PULLEY

    Click here

  20. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY

    1. A200644

      Remove the 9 bolts and engine water pump assembly and gasket from the timing chain cover sub-assembly.

    2. A296218

      Remove the 3 bolts and engine mounting bracket RH.

    3. A200634C03

      *1

      Seal Washer

      Remove the 21 bolts and seal washer.

    4. A200635C03

      *a

      Protective Tape

      Remove the timing chain cover sub-assembly by prying between the timing chain cover sub-assembly and cylinder head sub-assembly or cylinder block sub-assembly with a screwdriver.

      Note:

      Be careful not to damage the contact surfaces of the timing chain cover sub-assembly, cylinder block sub-assembly, and cylinder head sub-assembly.

      Tip:

      Tape the screwdriver tip before use.

    5. A197952

      Remove the 2 O-rings from the oil pan sub-assembly and oil strainer sub-assembly.

    6. A200637

      Using an 8 mm socket hexagon wrench, remove the plug from the timing chain cover sub-assembly.

  21. REMOVE TIMING CHAIN COVER OIL SEAL

    Click here

  22. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY

    Click here

  23. REMOVE NO. 2 CHAIN VIBRATION DAMPER

    Click here

  24. REMOVE TIMING CHAIN TENSION ARM

    Click here

  25. REMOVE CHAIN SUB-ASSEMBLY

    Click here

  26. REMOVE TIMING CHAIN GUIDE

    Click here

  27. 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. A198701C13

        *a

        Adhesive Tape Sealing Area

        *b

        Prick a Hole

        *c

        Adhesive Tape

        Clean the VVT oil hole on the intake side of the camshaft bearing cap, and completely seal the oil hole with adhesive tape or equivalent as shown in the illustration to prevent air from leaking.

        Note:

        Be sure to seal 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 adhesive tape sealing the oil hole as shown in the illustration. (Procedure A)

      3. A198702

        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:

        • The camshaft timing gear assembly may be turned in the advance direction without applying any force.

        • 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 camshaft bearing cap.

    3. A197613C12

      *a

      Do not Remove

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

      Note:

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

      • Be sure not to remove the other 4 bolts.

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

  28. REMOVE CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY

    1. A197612C12

      *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:

      • Be sure not to remove the other 4 bolts.

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

  29. REMOVE CAMSHAFT BEARING CAP

    Click here

  30. REMOVE OIL CONTROL VALVE FILTER

    1. A325183

      Remove the oil control valve filter from the camshaft bearing cap.

  31. REMOVE NO. 2 CAMSHAFT

    Click here

  32. REMOVE CAMSHAFT

    Click here

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

    1. A197616

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

      Tip:

      Arrange the removed parts in the correct order.

  34. REMOVE VALVE LASH ADJUSTER ASSEMBLY

    1. A197617

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

      Tip:

      Arrange the removed parts in the correct order.

  35. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY

    Click here

  36. REMOVE CYLINDER HEAD SUB-ASSEMBLY

    Click here

  37. REMOVE CYLINDER HEAD GASKET

    Click here

  38. REMOVE CYLINDER BLOCK WATER JACKET SPACER

    1. A198005

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

  39. REMOVE OIL PAN DRAIN PLUG

    1. A197622

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

  40. REMOVE OIL PAN SUB-ASSEMBLY

    1. A197623

      Uniformly loosen and remove the 10 bolts.

    2. A197624C03

      *a

      Protective Tape

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

      Note:

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

      Tip:

      Tape the screwdriver tip before use.

    3. A198049

      Remove the gasket from the cylinder block sub-assembly.

  41. REMOVE NO. 1 OIL PAN BAFFLE PLATE

    1. A197625

      Remove the 5 bolts and No. 1 oil pan baffle plate from the oil pan sub-assembly.

  42. REMOVE OIL STRAINER SUB-ASSEMBLY

    1. A197626

      Remove the 2 bolts and oil strainer sub-assembly from the oil pan sub-assembly.

  43. REMOVE RING PIN

    Note:

    It is not necessary to remove the ring pins unless they are being replaced.

    1. A294131

      Remove the 10 ring pins from the camshaft housing sub-assembly.

  44. REMOVE STRAIGHT PIN

    Note:

    It is not necessary to remove the straight pins unless they are being replaced.

    1. A294132

      Remove the 2 straight pins from the oil pan sub-assembly.