ENGINE UNIT > DISASSEMBLY

for Preparation Click here

CAUTION:

1. Prolonged and repeated contact with engine oil will result in the removal of natural oils from the skin, leading to dryness, irritation and dermatitis, used engine oil contains potentially harmful contaminants which may cause skin cancer.
   
2. Take precautions when replacing engine oil to minimize the risk of your skin making contract with used engine oil. Wear protective clothing and gloves that cannot be penetrated by oil. Wash skin with soap and water, or use water-less hand cleaner, to remove any used engine oil thoroughly. Do not use gasoline, thinner, or solvents.
   
3. Dispose of used oil and used oil filters at designated disposal sites in order to preserve the environment.
   

1. Remove the 2 bolts and the 2 engine hangers.
   

1. Remove the 3 spark plugs.
   

1. Remove the bolt and the camshaft position sensor.
   

1. Using a 19 mm deep socket wrench, remove the engine coolant temperature sensor.
   

   Text in Illustration 

   *1	19 mm Deep Socket Wrench

1. Remove the bolt and the camshaft timing oil control valve.
   

1. Remove the bolt and the crankshaft position sensor.
   

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

   Text in Illustration 

   *1	24 mm Deep Socket Wrench

1. Remove the bolt and the knock control sensor.
   

1. Using a 8 mm socket hexagon wrench, remove the head taper screw plug.
   

   Text in Illustration 

   *1	8 mm Socket Hexagon Wrench

2. Remove the oil control valve filter and gasket.
   

   Text in Illustration 

   *1	Oil Control Valve Filter
   *2	Gasket
   *3	Head Taper Screw Plug

1. Remove the oil filler cap.
   

2. Using a screwdriver, remove the gasket from the oil filler cap.
   

1. Remove the 16 bolts and the cylinder head cover sub-assembly.
   

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

1. Remove the ventilation valve.
   

   Text in Illustration 

   *1	Grommet
   *2	Ventilation Valve Sub-Assembly

2. Remove the grommet.
   

1. Remove the drain plug.
   

2. Remove the gasket.
   

1. Remove the 2 bolts and the oil filter bracket stay.
   

1. Remove the 12 bolts and 3 nuts.
   

2. Using an oil pan seal cutter, remove the oil pan.
   

   Text in Illustration 

   *1	Oil Pan Seal Cutter

   NOTICE:

   Be careful not to damage the contact surfaces of the oil pan.

1. Remove the 2 bolts and the oil strainer.
   

2. Remove the gasket.
   

1. Remove the 2 bolts and the water valve.
   

2. Remove the gasket.
   

1. Remove the bolt, the 2 nuts, and the No. 1 water by-pass pipe from the cylinder head and cylinder block.
   

2. Remove the gasket from the cylinder head.
   

3. Remove the gasket from the No. 1 water by-pass pipe.
   

1. Remove the 2 nuts and the water inlet.
   

1. Remove the 5 bolts and the water pump assembly.
   

2. Remove the gasket.
   

1. Using SST, remove the oil filter.
   

   SST

   09228-06501  
   

1. Remove the 2 bolts and the oil filter bracket.
   

2. Remove the gasket.
   

1. Using an 8 mm socket hexagon wrench, remove the timing gear cover tight plug.
   

   Text in Illustration 

   *1	8 mm Socket Hexagon Wrench

1. Turn the crankshaft pulley clockwise to align the timing mark on the pulley with the timing pointer of the timing chain cover.
   

   Text in Illustration 

   *1	Timing Mark
   *2	Timing Pointer

2. Make sure that the timing mark of the camshaft sprocket is at the top.
   

1. Using SST, hold the pulley in place and loosen the pulley bolt.
   

   SST

   09960-10010   (09962-01000, 09963-01000)
   

2. Using SST, remove the crankshaft pulley and pulley bolt.
   

   SST

   09950-40011   (09951-04010, 09953-04030, 09958-04011, 09955-04011, 09954-04010, 09952-04010)
   

1. Remove the 12 bolts.
   

2. Using a screwdriver with its tip wrapped in protective tape, remove the timing chain cover by prying between the timing cover and cylinder head or cylinder block.
   

   Text in Illustration 

   *1	Protective Tape

   NOTICE:

   Do not damage the contact surfaces of the cylinder head, cylinder block and timing chain cover.

3. Remove the 2 stud bolts.
   

1. Using a screwdriver with its tip wrapped in protective tape, pry out the oil seal.
   

   Text in Illustration 

   *1	Protective Tape

1. Remove the 3 bolts and the ventilation case sub-assembly.
   

1. Remove the oil pump gasket.
   

1. Turn the stopper plate of the chain tensioner clockwise and push in the plunger with the lock released.
   

   Text in Illustration 

   *1	Stopper Plate

2. Insert a hexagon wrench into the hole in the stopper plate to lock with the plunger pushed in.
   

   Text in Illustration 

   *1	Hexagon Wrench
   *2	Stopper Plate

3. Remove the 2 bolts and the timing chain tensioner.
   

1. Remove the bolt and the chain tensioner arm.
   

1. Remove the 2 bolts and the timing chain guide.
   

1. Remove the crankshaft timing chain gear or sprocket from the crankshaft.
   

1. Remove the crankshaft straight pin from the crankshaft.
   

1. Slightly turn the crankshaft clockwise.
   

   NOTICE:

   Do not allow the lifted valve and piston to come into the contact with each other when removing the camshaft.

2. Remove the bolt from the sprocket while holding the hexagonal portion of the camshaft.
   

3. Remove the camshaft timing sprocket from the camshaft.
   

1. Remove the bolt from the gear while holding the hexagonal portion of the No. 2 camshaft.
   

2. Remove the camshaft timing gear from No. 2 camshaft.
   

1. Remove the 15 bolts in the order shown in the illustration.
   

2. Remove the No. 1 camshaft bearing cap and No. 2 camshaft bearing caps.
   

3. Remove the 2 camshafts.
   

1. Remove the 4 bolts, and remove the oil seal retainer.
   

2. Remove the stud bolt.
   

1. Using a screwdriver with its tip wrapped in protective tape, pry out the oil seal.
   

   Text in Illustration 

   *1	Protective Tape

1. Remove the 12 valve lifters.
   

   NOTICE:

   1. Record the inscribed mark on the valve lifters for each valve after removing them.
      
   2. Arrange the valve lifters for each cylinder in order.
      

1. Using several steps, uniformly loosen and remove the 8 cylinder head bolts and 8 plate washers with an 8 mm bi-hexagon wrench in the sequence shown in the illustration.
   

   NOTICE:

   1. Head warpage or cracking could result from removing the bolts in the wrong order.
      
   2. Do not drop the washers into the cylinder head.
      

2. Remove the cylinder head from the cylinder block.
   

1. Remove the cylinder head gasket.