ENGINE UNIT DISASSEMBLY

PROCEDURE


  1. REMOVE OIL FILLER CAP SUB-ASSEMBLY


    1. A005EGX

      Remove the oil filler cap.

  2. REMOVE OIL FILLER CAP GASKET


    1. A005D9W

      Remove the oil filler cap gasket.

  3. REMOVE ENGINE COVER JOINT BOLT


    1. A005AAL

      Remove the 3 engine cover joint bolts.

  4. REMOVE WIRING HARNESS CLAMP BRACKET


    1. A005C64

      Remove the bolt and wiring harness clamp bracket.

  5. REMOVE SPARK PLUG

    Click here

  6. REMOVE CAMSHAFT POSITION SENSOR


    1. A005ABG

      Remove the bolt and camshaft position sensor.

  7. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY


    1. A005CEU

      Remove the bolt and camshaft timing oil control valve.

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

  8. REMOVE CRANKSHAFT POSITION SENSOR


    1. A005D1D

      Remove the bolt and crankshaft position sensor.

  9. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY


    1. A005BDG

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

  10. REMOVE KNOCK SENSOR


    1. A005DKR

      Remove the bolt and knock sensor.

  11. REMOVE ENGINE COOLANT TEMPERATURE SENSOR


    1. A005BYC

      Remove the engine coolant temperature sensor and gasket.

  12. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A005E66

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

      Note

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

    2. A005ES8

      Remove the 2 gaskets from the camshaft bearing cap.

  13. REMOVE CYLINDER HEAD COVER GASKET


    1. A005CIX

      Remove the cylinder head cover gasket.

  14. REMOVE SPARK PLUG TUBE GASKET


    1. A005B0E

      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. A005BG3

      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 subassembly.

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

      Tech Tips

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

  15. REMOVE OIL FILTER CAP ASSEMBLY

    Click here

  16. REMOVE WATER INLET SUB-ASSEMBLY


    1. A005EJF

      Remove the bolt, 2 nuts, inlet water sub-assembly and gasket.

  17. REMOVE WATER INLET SUB-ASSEMBLY STUD BOLT


    1. Using an E5 "TORX" socket wrench, remove the 2 stud bolts.

      Note

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

  18. SET NO. 1 CYLINDER TO TDC/COMPRESSION

    Click here

  19. REMOVE CRANKSHAFT PULLEY

    Click here

  20. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY

    Click here

  21. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY


    1. Using a 8mm deep socket wrench, remove the stud bolt from the engine mounting bracket RH.

    2. A005CL8

      Remove the 3 bolts and engine mounting bracket RH.

    3. A005BS1

      Remove the 4 bolts and oil filter bracket.

    4. A005CYW

      Remove the 2 O-rings.

    5. A005EX9E01
      Text in Illustration
      *1 Gasket

      Remove the 18 bolts and gasket.

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

      A005DQEE01
      Text in Illustration
      *1 Protective Tape

      Note


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

      • Pry the timing chain cover out evenly in order to prevent damaging the knock pins.

      Tech Tips

      Tape the screwdriver tip before use.

    7. A005BC2

      Remove the 3 O-rings.

    8. Place the timing chain cover on wooden blocks.

  22. REMOVE TIMING CHAIN COVER OIL SEAL


    1. Place the timing chain cover on wooden blocks.

    2. A005BBCE01
      Text in Illustration
      *1 Protective Tape
      *2 Wooden Block

      Using a screwdriver and hammer, knock out the oil seal.

      Tech Tips

      Tape the screwdriver tip before use.

      Note

      Do not damage the surface of the oil seal press fit hole.

  23. REMOVE CHAIN TENSIONER SLIPPER

    Click here

  24. REMOVE NO. 1 CHAIN VIBRATION DAMPER

    Click here

  25. REMOVE NO. 2 CHAIN VIBRATION DAMPER

    Click here

  26. REMOVE CHAIN SUB-ASSEMBLY

    Click here

  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. A005B3W

      Remove the crankshaft position sensor plate.

  30. REMOVE CRANKSHAFT TIMING GEAR KEY


    1. A0059V8E09
      Text in Illustration
      *1 Protective Tape

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

      Tech Tips

      Tape the screwdriver tip before use.

  31. INSPECT CAMSHAFT TIMING GEAR ASSEMBLY

    Click here

  32. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY

    Click here

  33. REMOVE CAMSHAFT TIMING SPROCKET

    Click here

  34. REMOVE CAMSHAFT BEARING CAP

    Click here

  35. REMOVE CAMSHAFT

    Click here

  36. REMOVE NO. 2 CAMSHAFT

    Click here

  37. REMOVE CAMSHAFT HOUSING STRAIGHT PIN

    Note

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

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


    1. A005B69

      Remove the 16 valve rocker arms.

      Tech Tips

      Arrange the removed parts in the correct order.

  39. REMOVE VALVE LASH ADJUSTER ASSEMBLY


    1. A005CZD

      Remove the 16 valve lash adjusters from the cylinder head.

      Tech Tips

      Arrange the removed parts in the correct order.

  40. REMOVE VALVE STEM CAP


    1. A005AFR

      Remove the 16 valve stem caps.

      Tech Tips

      Arrange the removed parts in the correct order.

  41. REMOVE OIL CONTROL VALVE FILTER


    1. A005BCL

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

  42. REMOVE NO. 1 CAMSHAFT BEARING


    1. A005AIU

      Remove the 2 camshaft bearings.

  43. REMOVE NO. 2 CAMSHAFT BEARING


    1. A005A5Q

      Remove the 2 camshaft bearings.

  44. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY

    Click here

  45. REMOVE CYLINDER HEAD SUB-ASSEMBLY

    Click here

  46. REMOVE CYLINDER HEAD GASKET

    Click here

  47. REMOVE VENTILATION VALVE SUB-ASSEMBLY


    1. A005BW3

      Remove the ventilation valve sub-assembly.

  48. REMOVE OIL PAN DRAIN PLUG


    1. A005AXH

      Remove the drain plug and gasket.

  49. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY

    Click here

  50. REMOVE OIL PUMP ASSEMBLY

    Click here

  51. REMOVE STIFFENING CRANKCASE ASSEMBLY


    1. A005C60

      Uniformly loosen and remove the 11 bolts.

    2. A005AKUE14
      Text in Illustration
      *1 Protective Tape

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

      Tech Tips

      Tape the screwdriver tip before use.

      Note

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

  52. REMOVE NO. 1 TAPER SCREW PLUG


    1. A005CNV

      Remove the 2 No. 1 taper screw plugs.

  53. REMOVE STIFFENING CRANKCASE STUD BOLT


    1. Using an E5 "TORX" socket wrench, remove the 2 stud bolts.

      Note

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

  54. REMOVE STIFFENING CRANKCASE RING PIN


    1. Remove the 2 ring pins.

      Note

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

  55. REMOVE ENGINE REAR OIL SEAL


    1. A005CSN

      Remove the engine rear oil seal from the cylinder block.