ENGINE UNIT DISASSEMBLY

PROCEDURE


  1. REMOVE ENGINE COVER JOINT


    1. A01W22L

      Remove the 3 engine cover joints.

  2. REMOVE SPARK PLUG

    Click here

  3. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY

    Click here

  4. REMOVE CAMSHAFT POSITION SENSOR

    Click here

  5. REMOVE OIL FILLER CAP SUB-ASSEMBLY


    1. Remove the oil filler cap sub-assembly from the cylinder head cover sub-assembly.

    2. Remove the gasket from the oil filler cap sub-assembly.

  6. REMOVE CRANKSHAFT POSITION SENSOR

    Click here

  7. REMOVE VENTILATION VALVE SUB-ASSEMBLY

    Click here

  8. REMOVE VENTILATION CASE SUB-ASSEMBLY


    1. A01W4BB

      Remove the 8 bolts and 2 nuts.

    2. A01W250

      Remove the ventilation case sub-assembly by prying between the ventilation case sub-assembly and cylinder block sub-assembly with a screwdriver.

      Note

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

      Tech Tips

      Tape the screwdriver tip before use.

  9. REMOVE SEPARATOR CASE


    1. A01W0G5

      Remove the 2 bolts, separator case and gasket.

  10. REMOVE NO. 1 WATER BY-PASS PIPE


    1. A01W0V8

      Remove the bolt, 2 nuts, No. 1 water by-pass pipe and gasket.

  11. REMOVE WATER INLET

    Click here

  12. REMOVE THERMOSTAT

    Click here

  13. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY


    1. A01W4E3

      Remove the bolt and V-ribbed belt tensioner assembly.

  14. REMOVE ENGINE WATER PUMP ASSEMBLY

    Click here

  15. REMOVE WATER INLET HOUSING


    1. A01W2CH

      Remove the 4 bolts, nut, water inlet housing and gasket.

  16. REMOVE CRANKSHAFT PULLEY


    1. A01W3BLE01
      Text in Illustration
      *a Hold
      *b Turn

      Using SST, hold the crankshaft pulley and loosen the pulley bolt. Further loosen the bolt until 2 or 3 threads are screwed into the crankshaft.

      SST
      09213-54015
      09330-00021

      Tech Tips

      SST (Crankshaft pulley holding tool) Fixing bolt part No. : 91551-80650(2 pcs)

    2. A01W5J0E09
      Text in Illustration
      *1 Pulley Bolt
      *a Hold
      *b Turn

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

      SST
      09950-50013   ( 09951-05010, 09952-05010, 09953-05020, 09954-05011 )

      Tech Tips

      Apply a lubricant to the threads and end of SST.

  17. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A01W5QT

      Remove the 16 bolts, 3 seal washers, cylinder head cover sub-assembly and cylinder head cover gasket.

    2. A01W1LV

      Remove the 3 camshaft bearing cap oil hole gaskets.

  18. REMOVE SPARK PLUG TUBE GASKET


    1. A01VZQN

      Using a screwdriver, pry out the 4 spark plug tube gaskets.

      Note

      Be careful not to damage the cylinder head cover sub-assembly.

      Tech Tips

      Tape the screwdriver tip before use.

  19. REMOVE ENGINE MOUNTING BRACKET RH

    Click here

  20. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY

    Click here

  21. REMOVE TIMING CHAIN COVER TIGHT PLUG


    1. A01W3NP

      Using a 14 mm hexagon wrench, remove the timing chain cover tight plug and gasket.

  22. REMOVE TIMING CHAIN COVER PLATE


    1. A01W54J

      Remove the 4 bolts, timing chain cover plate and gasket.

  23. REMOVE TIMING CHAIN COVER OIL SEAL

    Click here

  24. SET NO. 1 CYLINDER TO TDC/COMPRESSION

    Click here

  25. REMOVE TIMING CHAIN GUIDE

    Click here

  26. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY

    Click here

  27. REMOVE CHAIN TENSIONER SLIPPER

    Click here

  28. REMOVE CHAIN SUB-ASSEMBLY


    1. Remove the chain sub-assembly.

  29. REMOVE NO. 1 CHAIN VIBRATION DAMPER

    Click here

  30. REMOVE CRANKSHAFT TIMING SPROCKET


    1. A01W4DC

      Remove the crankshaft timing sprocket from the crankshaft.

  31. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY

    Click here

  32. REMOVE CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY

    Click here

  33. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY

    Click here

  34. REMOVE CAMSHAFT BEARING CAP

    Click here

  35. REMOVE OIL CONTROL VALVE FILTER


    1. A01W4GF

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

  36. REMOVE CAMSHAFT

    Click here

  37. REMOVE NO. 1 CAMSHAFT BEARING


    1. A01W3BK

      Remove the No. 1 camshaft bearing from the No. 1 camshaft bearing cap.

  38. REMOVE NO. 2 CAMSHAFT BEARING


    1. A01W0WN

      Remove the No. 2 camshaft bearing from the camshaft housing sub-assembly.

  39. REMOVE CAMSHAFT HOUSING STUD BOLT

    Note

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

  40. REMOVE CAMSHAFT BEARING CAP SETTING RING PIN

    Note

    It is not necessary to remove the camshaft bearing cap setting ring pin unless it is being replaced.

  41. REMOVE CAMSHAFT HOUSING STRAIGHT PIN

    Note

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

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

    Click here

  43. REMOVE VALVE LASH ADJUSTER ASSEMBLY

    Click here

  44. REMOVE VALVE STEM CAP

    Click here

  45. REMOVE CYLINDER HEAD SUB-ASSEMBLY

    Click here

  46. REMOVE CYLINDER HEAD GASKET

    Click here

  47. REMOVE CYLINDER BLOCK WATER JACKET SPACER


    1. A01W0OH

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

      Note

      Be sure to remove the cylinder block water jacket spacer. If it is not removed, it may fall and become damaged when the cylinder block sub-assembly is inverted.

  48. REMOVE OIL FILTER CAP ASSEMBLY

    Click here

  49. REMOVE OIL FILTER BRACKET CLIP


    1. A01VZVG

      Remove the oil filter bracket clip from the stiffening crankcase assembly.

  50. REMOVE OIL PAN DRAIN PLUG


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

  51. REMOVE OIL PAN SUB-ASSEMBLY


    1. A01W57CE08
      Text in Illustration
      *1 Nut

      Remove the 11 bolts and 2 nuts.

    2. A01W2RA

      Insert the blade of an oil pan seal cutter between the oil pan sub-assembly and stiffening crankcase assembly, cut off the applied sealer and remove the oil pan sub-assembly.

      Note


      • Be careful not to damage the stiffening crankcase assembly contact surface of the oil pan sub-assembly.

      • Be careful not to damage the stiffening crankcase flange.

  52. REMOVE OIL STRAINER SUB-ASSEMBLY


    1. A01W4QW

      Remove the 3 bolts, oil strainer sub-assembly and gasket.

  53. REMOVE NO. 1 OIL PAN BAFFLE PLATE


    1. A01W27S

      Remove the 5 bolts and No. 1 oil pan baffle plate.

  54. INSPECT CRANKSHAFT BACKLASH


    1. A01W20E

      Using a dial indicator, measure the backlash of the crankshaft and balance shaft as shown in the illustration.

      Standard backlash
      0.05 to 0.20 mm (0.00197 to 0.00787 in.)
      Maximum backlash
      0.20 mm (0.00787 in.)

      If the backlash is more than the maximum, replace the engine balancer assembly.

  55. REMOVE ENGINE BALANCER ASSEMBLY


    1. A01W0SC

      Remove the 7 bolts and engine balancer assembly.

      Note

      Do not disassemble the engine balancer assembly.

  56. INSPECT BALANCE SHAFT THRUST CLEARANCE

    Click here

  57. REMOVE STIFFENING CRANKCASE ASSEMBLY


    1. A01W2CK

      Remove the 7 bolts.

    2. A01W27OE03
      Text in Illustration
      *a LH Side
      *b RH Side

      Using a screwdriver, remove the stiffening crankcase assembly by prying between the stiffening crankcase assembly and cylinder block sub-assembly at the places shown in the illustration.

      Note

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

      Tech Tips

      Tape the screwdriver tip before use.

  58. REMOVE STIFFENING CRANKCASE STUD BOLT

    Note

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

  59. REMOVE STIFFENING CRANKCASE RING PIN

    Note

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

  60. REMOVE REAR ENGINE OIL SEAL


    1. A01W0NN

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