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. A173601

      Remove the 2 bolts and 2 camshaft position sensors.

  6. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY

    1. A173602

      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

    Click here

  9. REMOVE KNOCK CONTROL SENSOR

    1. A152587

      Remove the bolt and knock control sensor.

  10. REMOVE ENGINE COOLANT TEMPERATURE SENSOR

    1. A214078

      Remove the engine coolant temperature sensor and gasket.

  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 gasket 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. A352811

      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.

  14. REMOVE OIL FILTER CAP ASSEMBLY

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  15. REMOVE WATER INLET HOUSING

    1. A150906

      Remove the 3 bolts, water inlet housing and gasket.

  16. REMOVE WATER INLET HOUSING STUD BOLT

    Note:

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

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

  17. SET NO. 1 CYLINDER TO TDC/COMPRESSION

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  18. REMOVE CRANKSHAFT PULLEY

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  19. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY

    Click here

  20. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY

    Click here

  21. REMOVE TIMING CHAIN COVER OIL SEAL

    Click here

  22. REMOVE NO. 1 GENERATOR BRACKET

    1. A150905

      Remove the 4 bolts and No. 1 generator bracket.

  23. REMOVE CHAIN TENSIONER SLIPPER

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  24. REMOVE NO. 1 CHAIN VIBRATION DAMPER

    Click here

  25. REMOVE CHAIN SUB-ASSEMBLY

    Click here

  26. REMOVE CRANKSHAFT TIMING SPROCKET

    Click here

  27. REMOVE NO. 2 CHAIN SUB-ASSEMBLY

    Click here

  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. A150909C09

      *a

      Protective Tape

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

      Tip:

      Tape the screwdriver tip before use.

  30. INSPECT CAMSHAFT TIMING GEAR ASSEMBLY

    Click here

  31. INSPECT CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY

    Click here

  32. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY

    Click here

  33. REMOVE CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY

    Click here

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

    Click here

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

    Click here

  36. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY

    Click here

  37. REMOVE CONTINUOUSLY VARIABLE VALVE LIFT CONTROLLER ASSEMBLY

    1. A173790

      Using a screwdriver, slide the control actuator clip from the valve lift 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. A209172

      Remove the bolt.

    3. A174268

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

      Note:

      • Do not forcibly pry the valve lift control actuator connector.

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

    4. A174269

      Using a Magnet Hand, remove the straight pin from the valve lift control actuator connector.

      Tip:

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

    5. A174270C02

      *1

      Continuously Variable Valve Lift Controller Assembly

      *2

      Valve Lift Control Actuator Connector

      *3

      O-Ring

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

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

      Note:

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

    7. Rotate the valve lift control actuator connector and remove it from the valve rocker shaft.

  38. REMOVE CAMSHAFT HOUSING STUD BOLT

    Note:

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

    1. A173607

      Using an E7 "TORX" socket wrench, remove the 2 camshaft housing stud bolts.

  39. REMOVE CAMSHAFT HOUSING RING PIN

    Note:

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

  40. REMOVE CYLINDER HEAD SUB-ASSEMBLY

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  41. REMOVE CYLINDER HEAD GASKET

    Click here

  42. REMOVE VENTILATION VALVE SUB-ASSEMBLY

    Click here

  43. REMOVE OIL PAN DRAIN PLUG

    1. A150893

      Remove the oil pan drain plug and gasket.

  44. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY

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  45. REMOVE OIL PUMP ASSEMBLY

    Click here

  46. REMOVE STIFFENING CRANKCASE ASSEMBLY

    1. A150897

      Uniformly loosen and remove the 11 bolts.

    2. A150898C10

      *a

      Protective Tape

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

      Tip:

      Tape the screwdriver tip before use.

      Note:

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

  47. REMOVE NO. 1 TAPER SCREW PLUG

    1. A400030

      Remove the No. 1 taper screw plug.

  48. REMOVE STIFFENING CRANKCASE STUD BOLT

    Note:

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

  49. REMOVE STIFFENING CRANKCASE RING PIN

    Note:

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

  50. REMOVE REAR ENGINE OIL SEAL

    1. A206144

      Remove the rear engine oil seal from the cylinder block sub-assembly.