ENGINE UNIT DISASSEMBLY

PROCEDURE


  1. REMOVE OIL FILLER CAP SUB-ASSEMBLY


    1. B005XKB

      Remove the oil filler cap.

  2. REMOVE OIL FILLER CAP GASKET


    1. B005XJF

      Remove the oil filler cap gasket.

  3. REMOVE ENGINE COVER JOINT BOLT


    1. B005Z9E

      Remove the 3 engine cover joint bolts.

  4. REMOVE WIRING HARNESS CLAMP BRACKET


    1. B005ZUI

      Remove the bolt and wiring harness clamp bracket.

  5. REMOVE SPARK PLUG

    Click here

  6. REMOVE CAMSHAFT POSITION SENSOR


    1. B005Z2Q

      Remove the bolt and camshaft position sensor.

  7. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY


    1. B005XLQ

      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. B005YW1

      Remove the bolt and crankshaft position sensor.

  9. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY


    1. B005ZFF

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

  10. REMOVE KNOCK SENSOR


    1. B005XTR

      Remove the bolt and knock sensor.

  11. REMOVE ENGINE COOLANT TEMPERATURE SENSOR


    1. B005ZHE

      Remove the engine coolant temperature sensor and gasket.

  12. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY


    1. B005YT5

      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. B005YVV

      Remove the 2 gaskets from the camshaft bearing cap.

  13. REMOVE CYLINDER HEAD COVER GASKET


    1. B005Y63

      Remove the cylinder head cover gasket.

  14. REMOVE SPARK PLUG TUBE GASKET


    1. B005XMR

      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. B005Y5F

      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

    Click here

  16. REMOVE WATER INLET SUB-ASSEMBLY


    1. B005ZS3

      Type A:


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

    2. B005ZKO

      Type B:


      1. Remove the 3 bolts, water inlet 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. B005ZOU

      Remove the 3 bolts and engine mounting bracket RH.

    3. B005Z1Y

      Remove the 4 bolts and oil filter bracket.

    4. B005Y5D

      Remove the 2 O-rings.

    5. B005ZJ9E01
      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.

      B005YGQE01
      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. B005Y3I

      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. B005XG8E01
      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. B005YAI

      Remove the crankshaft position sensor plate.

  30. REMOVE CRANKSHAFT TIMING GEAR KEY


    1. B005Y93E09
      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. B005Y6N

      Remove the 16 valve rocker arms.

      Tech Tips

      Arrange the removed parts in the correct order.

  39. REMOVE VALVE LASH ADJUSTER ASSEMBLY


    1. B005XLK

      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. B005YS5

      Remove the 16 valve stem caps.

      Tech Tips

      Arrange the removed parts in the correct order.

  41. REMOVE OIL CONTROL VALVE FILTER


    1. B005ZK5

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

  42. REMOVE NO. 1 CAMSHAFT BEARING


    1. B005Z67

      Remove the 2 camshaft bearings.

  43. REMOVE NO. 2 CAMSHAFT BEARING


    1. B005ZB0

      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. B005YI1

      Remove the ventilation valve sub-assembly.

  48. REMOVE OIL PAN DRAIN PLUG


    1. B005YUH

      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. B005ZJ1

      Uniformly loosen and remove the 11 bolts.

    2. B005ZMVE14
      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. Type A:


      1. B005Z10

        Remove the 2 No. 1 taper screw plugs.

    2. Type B:


      1. B005XNX

        Remove the No. 1 taper screw plug.

  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. B005ZAJ

      Remove the engine rear oil seal from the cylinder block.