ENGINE UNIT DISASSEMBLY


  1. REMOVE OIL FILLER CAP SUB-ASSEMBLY

  2. REMOVE NO. 2 CYLINDER HEAD COVER SUB-ASSEMBLY


    1. Remove the 2 bolts and the No. 2 cylinder head cover.

  3. REMOVE CYLINDER HEAD COVER CUSHION RUBBER


    1. Remove the cylinder head cover cushion rubber from the No. 2 cylinder head cover.

  4. REMOVE CYLINDER HEAD COVER STAY


    1. Remove the 2 cylinder head cover stays from the No. 2 cylinder head cover.

  5. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY


    1. Remove the 2 bolts and cylinder head cover.

    2. Remove the 2 cylinder head cover spacers from the cylinder head cover.

  6. REMOVE CYLINDER HEAD COVER CUSHION


    1. Remove the 2 cylinder head cover cushions from the cylinder head cover.

  7. REMOVE CYLINDER HEAD COVER GASKET


    1. Remove the cylinder head cover gasket from the cylinder head cover.

  8. REMOVE NO. 1 VALVE ROCKER SHAFT SUB-ASSEMBLY


    1. A01CI9IE01

      Loosen the lock nut at the top of the rocker arms, then loosen the adjusting screws completely.

      Note

      If the adjusting screws are not loosened, the rocker shaft may bend when the rocker arm support bolts are loosened.

    2. A01CGKLE01

      Loosen the 5 rocker arm support bolts in the order shown in the illustration.

    3. Remove the bolts and the No. 1 valve rocker shaft.

  9. REMOVE VALVE PUSH ROD

    Note

    Organize the parts so that each part location can be remembered for reassembly.

  10. REMOVE VALVE BRIDGE

    Note

    Organize the parts so that each part location can be remembered for reassembly.

  11. REMOVE CYLINDER HEAD SUB-ASSEMBLY


    1. A01CHHQE01

      Remove the cylinder head bolts in the order shown in the illustration.

    2. Lift and remove the cylinder head from the cylinder block.

    3. Remove the cylinder head gasket.

  12. REMOVE VALVE LIFTER

    Note

    Organize the parts so that each part location can be remembered for reassembly.

  13. REMOVE CRANKSHAFT PULLEY


    1. A01CIN3

      Using a 46 mm socket wrench, remove the nut, spacer and pulley.

      Tech Tips

      Insert a screwdriver through the inspection hole of the flywheel housing into the ring gear of the flywheel to keep it from turning together with the crankshaft.

  14. REMOVE FLYWHEEL HOUSING STAY RH


    1. Remove the 4 bolts and the flywheel housing stay.

  15. REMOVE FLYWHEEL HOUSING STAY LH


    1. Remove the 4 bolts and the flywheel housing stay.

  16. REMOVE FRONT NO. 1 ENGINE MOUNTING BRACKET RH


    1. Remove the 4 bolts and the front No. 1 engine mounting bracket.

  17. REMOVE FRONT NO. 1 ENGINE MOUNTING BRACKET LH


    1. Remove the 4 bolts and the front No. 1 engine mounting bracket.

  18. REMOVE OIL PAN SUB-ASSEMBLY


    1. Remove the 26 bolts from the oil pan.

    2. A01CIIS

      Insert the blade of an oil pan seal cutter between the crankcase and oil pan. Cut through the applied sealer and remove the oil pan.

      Note

      Do not damage the contact surfaces of the cylinder block and oil pan.

  19. REMOVE OIL STRAINER SUB-ASSEMBLY


    1. Remove the 3 bolts and strainer.

    2. Remove the O-ring.

  20. REMOVE OIL SEPARATOR ASSEMBLY


    1. Remove the 5 bolts and the oil separator from the timing gear case.

    2. Remove the 2 O-rings.

  21. REMOVE TIMING GEAR CASE


    1. A01CJ31

      Remove the 15 bolts.

    2. Using a screwdriver with its tip wrapped with protective tape, pry off the timing gear case.

      Note

      Do not damage the contact surfaces of the timing gear case, cylinder block and cylinder head.

  22. REMOVE TIMING CHAIN OR BELT COVER OIL SEAL


    1. A01CHQXE03

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

      Tech Tips

      Use wooden blocks and a shop rag or piece of cloth to prevent damage to the timing gear case.

  23. INSPECT NO. 2 IDLE GEAR THRUST CLEARANCE


    1. A01CH3H

      Using a feeler gauge, measure the thrust clearance between the No. 2 idle gear thrust plate and No. 2 idle gear.

      Standard thrust clearance
      0.103 to 0.164 mm (0.0040 to 0.0064 in.)
      Maximum thrust clearance
      0.30 mm (0.0118 in.)

      If the thrust clearance is greater than the maximum, replace the No. 2 idle gear thrust plate and No. 2 idle gear.

  24. INSPECT NO. 2 IDLE GEAR BACKLASH


    1. A01CIVF

      Using a dial indicator, measure the backlash between the No. 1 idle gear and No. 2 idle gear.

      Standard backlash
      0.036 to 0.227 mm (0.0014 to 0.0089 in.)
      Maximum backlash
      0.30 mm (0.0118 in.)

      If the backlash is greater than the maximum, replace the No. 1 idle gear and No. 2 idle gear.

  25. REMOVE NO. 2 IDLE GEAR THRUST PLATE


    1. Remove the 2 bolts and No. 2 idle gear thrust plate.

  26. REMOVE NO. 2 IDLE GEAR SUB-ASSEMBLY

  27. REMOVE NO. 2 IDLE GEAR SHAFT


    1. Remove the 2 bolts and No. 2 idle gear shaft.

    2. Remove the O-ring.

  28. REMOVE LOCK PLATE


    1. Remove the 3 bolts and plate from the end plate.

  29. INSPECT CAMSHAFT TIMING GEAR BACKLASH


    1. A01CHFK

      Using a dial indicator, measure the backlash between the camshaft timing gear and No. 1 idle gear.

      Standard backlash
      0.069 to 0.203 mm (0.0027 to 0.0079 in.)
      Maximum backlash
      0.30 mm (0.0118 in.)

      If the backlash is greater than the maximum, replace the camshaft timing gear and No. 1 idle gear.

  30. REMOVE CAMSHAFT


    1. Remove the 2 bolts and camshaft.

  31. INSPECT OIL PUMP GEAR BACKLASH


    1. A01CIWO

      Using a dial indicator, measure the backlash between the oil pump gear and No. 1 idle gear.

      Standard backlash
      0.065 to 0.215 mm (0.0025 to 0.0084 in.)
      Maximum backlash
      0.30 mm (0.0118 in.)

      If the backlash is greater than the maximum, replace the pump and No. 1 idle gear.

  32. INSPECT NO. 1 IDLE GEAR THRUST CLEARANCE


    1. A01CILF

      Using a feeler gauge, measure the thrust clearance between the No. 1 idle gear thrust plate and No. 1 idle gear.

      Standard thrust clearance
      0.103 to 0.164 mm (0.0040 to 0.0064 in.)
      Maximum thrust clearance
      0.30 mm (0.0118 in.)

      If the thrust clearance is greater than the maximum, replace the No. 1 idle gear thrust plate and No. 1 idle gear.

  33. INSPECT NO. 1 IDLE GEAR BACKLASH


    1. A01CIHW

      Using a dial indicator, measure the backlash between the crankshaft timing gear and No. 1 idle gear.

      Standard backlash
      0.035 to 0.193 mm (0.0014 to 0.0075 in.)
      Maximum backlash
      0.30 mm (0.0118 in.)

      If the backlash is greater than the maximum, replace the crankshaft timing gear and No. 1 idle gear.

  34. REMOVE NO. 1 IDLE GEAR SHAFT


    1. A01CJ75E01

      Remove the bolt.

    2. Using SST, remove the No. 1 idle gear shaft.

      SST
      09910-00015   ( 09911-00011, 09912-00010 )

      Note

      When removing the gear shaft, hold the No. 1 idle gear by hand to prevent the No. 1 gear and No. 1 idle gear thrust plate from falling.

  35. REMOVE NO. 1 IDLE GEAR SUB-ASSEMBLY

  36. REMOVE NO. 1 IDLE GEAR THRUST PLATE

  37. REMOVE CRANKSHAFT TIMING GEAR OR SPROCKET


    1. A01CI0JE01

      Using SST, remove the crankshaft timing gear or sprocket.

      SST
      09950-40011   ( 09951-04010, 09952-04010, 09953-04020, 09954-04010, 09955-04051 )

  38. REMOVE OIL PUMP ASSEMBLY


    1. Remove the 7 bolts and oil pump.

  39. REMOVE OIL PUMP COVER GASKET


    1. Remove the gasket from the oil pump.

  40. REMOVE FRONT END PLATE


    1. A01CGQY

      Remove the 4 bolts and front end plate.

  41. REMOVE FRONT END PLATE GASKET


    1. Remove the front end plate gasket from the front end plate.

  42. REMOVE FLYWHEEL SUB-ASSEMBLY


    1. A01CJBW

      Temporarily install the 4 bolts in the positions of the cylinder block shown in the illustration to prevent the cables from sliding toward the center of the block.

    2. Attach the 2 cables to the cylinder block.

      Tech Tips

      The cables must be attached outside the installed bolts.

    3. Using a chain block and an engine sling device, remove the cylinder block from the engine stand.

    4. A01CHL7E01

      Place the cylinder block on wooden blocks on a workbench.

    5. Remove the 4 bolts from the cylinder block.

    6. A01CIN3

      Insert a screwdriver through the inspection hole of the flywheel housing into the ring gear of the flywheel to keep it from turning together with the crankshaft.

    7. A01CHU7E01

      Uniformly loosen and remove the 6 bolts in the order shown in the illustration.

    8. Remove the flywheel.

      Note

      The flywheel is heavy. When removing, be careful not to drop it.

  43. REMOVE FLYWHEEL RING GEAR


    1. A01CHOT

      Using a torch, heat the ring gear evenly to approximately 200°C (392°F).

      Note

      Be careful not to overheat the ring gear.

      CAUTION:

      Do not touch the ring gear and flywheel while they are hot.

    2. A01CIXX

      Using a brass bar and hammer, uniformly strike all around the ring gear and remove the gear.

      CAUTION:

      After removing, allow the ring gear to cool before handling.

  44. REMOVE FLYWHEEL HOUSING


    1. Remove the 14 bolts from the cylinder block.

    2. Using a screwdriver with its tip wrapped with protective tape, pry off the flywheel housing.

  45. REMOVE ENGINE REAR OIL SEAL


    1. A01CIXME02

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

      Tech Tips

      Use wooden blocks and a shop rag or piece of cloth to prevent damage to the flywheel housing.

  46. REMOVE OIL CHECK VALVE SUB-ASSEMBLY


    1. Remove the bolt, the oil check valve and gasket.