ENGINE UNIT DISASSEMBLY


  1. REMOVE OIL FILLER CAP SUB-ASSEMBLY

  2. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY


    1. Remove the 8 bolts, 2 nuts, cylinder head cover and gasket.

  3. REMOVE CAMSHAFT TIMING PULLEY


    1. A01KEZ4E01
      Text in Illustration
      *a Turn

      Set the No. 1 cylinder to approx. 90° BTDC/compression.

      Tech Tips

      Set the No.1 cylinder to 90° BTDC/compression to avoid interference with the piston top and valve head.


      1. Using the crankshaft pulley bolt, turn the crankshaft 90° counterclockwise, and put the timing mark of the crankshaft timing pulley with the protrusion of the timing belt case.

    2. A01KFDDE01

      Using SST, loosen the pulley bolt.

      SST
      09960-10010   ( 09962-01000, 09963-01000 )
    3. A01KIACE01

      Using SST, disconnect the timing pulley from the camshaft.

    4. Remove the pulley bolt and timing pulley.

    5. Remove the seat key.

      SST
      09950-50013   ( 09951-05010, 09952-05010, 09953-05010, 09954-05021 )

  4. REMOVE TIMING BELT NO. 2 COVER


    1. Remove the 4 bolts and timing belt cover.

  5. REMOVE CAMSHAFT OIL SEAL RETAINER


    1. Remove the 4 bolts, retainer and gasket.

  6. REMOVE OIL SEAL RETAINER, NO.2 OIL SEAL

    Tech Tips

    There are 2 methods ((a) and (b)) to remove the oil seal.


    1. If the camshaft oil seal retainer is removed from the cylinder head:


      1. A01KIKV

        Using a screwdriver and hammer, tap out the oil seal.

    2. A01KEORE01
      Text in Illustration
      *a Cut Position

      If the camshaft oil seal retainer is installed to the cylinder head:


      1. Using a knife, cut off the oil seal lip.

      2. Using a screwdriver, pry out the oil seal.

        Note

        Be careful not to damage the camshaft. Tape the screwdriver tip.

  7. REMOVE CAMSHAFT


    1. A01KHIZE01
      Text in Illustration
      *1 key Groove
      *a Upward

      Set the key groove of the camshaft, facing upward by turning the camshaft with a wrench.

    2. A01KHYQ

      Uniformly loosen and remove the 10 bearing cap bolts, in several passes, in the sequence shown.

    3. Remove the 5 bearing caps and camshaft.

    4. Remove the 10 bearings from the bearing caps and cylinder head.

      Tech Tips

      Arrange the bearings incorrect order.

  8. REMOVE CYLINDER HEAD SUB-ASSEMBLY


    1. A01KESM

      Uniformly loosen and remove the 18 cylinder head bolts, in several passes, in the sequence shown.

      Note

      Head warpage or cracking could result from removing bolts in incorrect order.

    2. A01KGZ6

      Lift the cylinder head from the dowels on the cylinder block, and place the cylinder head on wooden blocks on a bench.

      Tech Tips

      If the cylinder head is difficult to lift off, pry with a screwdriver between the cylinder head and block.

      Note

      Be careful not to damage the contact surfaces of the cylinder head and cylinder block.

  9. REMOVE TIMING BELT IDLER SUB-ASSEMBLY NO.1


    1. A01KHYI

      Remove the 2 bolts (A and B).

    2. Loosen the bolt (C), and remove the idler pulley.

  10. REMOVE TIMING BELT IDLER SUB-ASSEMBLY NO.2


    1. Remove the bolt, idler pulley and spacer.

  11. REMOVE WATER PUMP ASSEMBLY


    1. Remove the 6 bolts, tension spring bracket, water pump and gasket.

  12. REMOVE CRANKSHAFT TIMING PULLEY

    A01KFKSE01

    Tech Tips

    If the pulley cannot be remove by screwdriver, use SST, remove the timing pulley.

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

  13. REMOVE OIL PAN SUB-ASSEMBLY


    1. Remove the 14 bolts and 4 nuts.

    2. A01KFPUE01
      Text in Illustration
      *1 Oil Pan Seal Cutter

      Insert the blade of oil pan seal cutter between the oil pan and cylinder block, and cut off applied sealer and remove the oil pan.

      Note


      • Do not use oil pan seal cutter for the timing belt case side and rear oil seal retainer.

      • Be careful not to damage the oil pan flange.

  14. REMOVE OIL STRAINER SUB-ASSEMBLY


    1. Remove the 2 bolts, 2 nuts, oil strainer and gasket.

  15. REMOVE TIMING GEAR CASE SUB-ASSEMBLY


    1. Remove the 5 bolts, timing belt case and gasket.

  16. REMOVE TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL

    Tech Tips

    There are 2 methods ((a) and (b)) to remove the oil seal.


    1. If the rear oil seal retainer is removed from the cylinder block:


      1. A01KENC

        Using a screwdriver and hammer, tap out the oil seal.

    2. A01KF32E01
      Text in Illustration
      *a Cut Position

      If the oil pump is installed to the cylinder block:


      1. Using a knife, cut off the oil seal lip.

      2. Using a screwdriver, pry out the oil seal.

        Note

        Be careful not to damage the crankshaft. Tape the screwdriver tip.

  17. REMOVE ENGINE REAR OIL SEAL RETAINER


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

  18. REMOVE ENGINE REAR OIL SEAL

    Tech Tips

    There are 2 methods ((a) and (b)) to remove the oil seal.


    1. If the rear oil seal retainer is removed from the cylinder block:


      1. A01KH6S

        Using a screwdriver and hammer, tap out the oil seal.

    2. A01KFT4E01
      Text in Illustration
      *a Cut Position

      If the rear oil seal retainer is installed to the cylinder block:


      1. Using a knife, cut off the oil seal lip.

      2. Using a screwdriver, pry out the oil seal.

        Note

        Be careful not to damage the crankshaft. Tape the screwdriver tip.