ENGINE UNIT DISASSEMBLY


  1. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A01388RE01

      Remove the 13 bolts and 2 nuts in the order shown in the illustration.

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

  2. REMOVE OIL FILTER SUB-ASSEMBLY


    1. A0136XXE01

      Using SST, remove the oil filter.

      SST
      09228-06501

  3. REMOVE OIL FILTER BRACKET


    1. A013897E03

      Remove the 3 bolts, oil filter bracket and oil filter bracket gasket.

  4. REMOVE ENGINE WATER PUMP ASSEMBLY

    A0137L2

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

    2. Remove the water pump gasket.

  5. SET NO. 1 CYLINDER TO TDC/EXHAUST

    A0138UBE02
    Text in Illustration
    *1 Timing Mark
    *2 Timing Pointer

    1. Turn the crankshaft pulley clockwise to align the timing mark (0°) of the pulley with the timing pointer of the timing chain cover.

    2. A0138JRE05
      Text in Illustration
      *1 Timing Mark

      Check that the timing mark of the camshaft timing sprocket is at the top as shown in the illustration.

      Tech Tips

      If not, turn the crankshaft pulley 1 complete revolution (360°) so that the timing mark comes to the top.

  6. REMOVE OIL PAN SUB-ASSEMBLY


    1. Remove the 13 bolts and 2 nuts.

    2. A0138YAE02
      Text in Illustration
      *1 Oil Pan Seal Cutter

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

      Note

      Do not damage the flange of the oil pan.

  7. REMOVE OIL STRAINER SUB-ASSEMBLY


    1. A013856

      Remove the 3 bolts and the oil strainer.

    2. Remove the oil strainer gasket.

  8. REMOVE CRANKSHAFT PULLEY


    1. A0137GLE01

      Using SST, hold the crankshaft pulley and loosen the pulley bolt.

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

    2. Remove the crankshaft pulley.

  9. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY


    1. A0136CXE01

      Remove the 11 bolts.

    2. A0138NPE02

      Remove the timing chain or belt cover by prying between the timing chain or belt cover and cylinder head or cylinder block with a screwdriver.

      Note

      Be careful not to damage the contact surfaces of the cylinder head, cylinder block and timing chain cover.

      Tech Tips

      Tape the screwdriver tip before use.

  10. REMOVE OIL PUMP GASKET


    1. A0137PCE02

      Remove the oil pump gasket.

  11. REMOVE TIMING CHAIN COVER OIL SEAL


    1. A013864E02

      Using a screwdriver with its tip taped, pry out the oil seal.

      Tech Tips

      Tape the screwdriver tip before use.

  12. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY


    1. A0136TWE01
      Text in Illustration
      *1 Plunger
      *2 Stopper Plate
      *a Push
      *b Released

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

    2. A0137K5

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

    3. A0138D7

      Remove the 2 bolts and the chain tensioner.

  13. REMOVE TIMING CHAIN TENSION ARM

    A01378O

    1. Remove the bolt and the timing tension arm.

  14. REMOVE CHAIN SUB-ASSEMBLY

  15. REMOVE TIMING CHAIN GUIDE

    A0136IB

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

  16. REMOVE CRANKSHAFT TIMING GEAR OR SPROCKET


    1. A0138KQ

      Remove the crankshaft timing gear or sprocket.

    2. A0138Q0

      Remove the key.

  17. REMOVE CAMSHAFT TIMING SPROCKET ASSEMBLY

    A0138FZE03
    Text in Illustration
    *a Turn
    *b Hold

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

    2. Remove the camshaft timing sprocket from the camshaft.

  18. REMOVE CAMSHAFT TIMING GEAR OR SPROCKET

    A01364CE03
    Text in Illustration
    *a Turn
    *b Hold

    1. Remove the bolt from the camshaft timing gear or sprocket while holding the hexagonal portion of the camshaft.

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

  19. REMOVE CAMSHAFTS


    1. A0136CVE03

      Temporarily tighten the bolt of the crankshaft.

    2. Turn the crankshaft by approximately 90° in the engine revolution direction at the point where the No. 1 piston is set to the TDC/exhaust so that the lifted valve and piston do not contact each other when removing the camshaft.

    3. A0138H4E02
      Text in Illustration
      *1 No. 1 Camshaft Bearing Cap
      *2 No. 2 Camshaft Bearing Cap

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

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

    5. A0136MS

      Remove the camshafts No. 1 and No. 2.

  20. REMOVE VALVE LIFTER


    1. A0138XG

      Remove the 12 valve lifters.

      Note


      • Record each inscribed mark on the valve lifters for each valve after removing them.

      • Arrange the valve lifters for each cylinder.

  21. REMOVE CYLINDER HEAD SUB-ASSEMBLY


    1. A0138QKE02

      Using several steps, uniformly loosen and remove the 8 cylinder head bolts in the order shown in the illustration.

    2. A0137BN

      Remove the cylinder head and cylinder head gasket from the cylinder block.

  22. REMOVE VALVE


    1. A013913E02

      Using SST, remove the intake and exhaust valve spring retainer locks, valve retainer springs, and compression springs.

      SST
      09202-87002   ( 09202-00010 )

      Note

      Arrange the removed parts for each cylinder.

    2. A013937

      Remove the intake and exhaust valves.

      Note

      Arrange the valves for each cylinder.

    3. A0137DNE01
      Text in Illustration
      *1 Needle-nose Pliers

      Using needle-nose pliers, remove the valve stem oil seals.

    4. A0137BQ

      Remove the valve spring seats.

  23. CLEAN CYLINDER HEAD SUB-ASSEMBLY


    1. A0136D9

      Using a scraper, clean the cylinder block surface and manifold of the cylinder head.

      CAUTION:


      • Be sure to wear protective goggles while servicing.

      • Do not damage the cylinder head.

      • Do not drop cylinder head gasket material into the water jacket.

  24. INSPECT CYLINDER HEAD SUB-ASSEMBLY


    1. Using a straightedge and feeler gauge, measure warpage on the contact surface indicated in the illustration below.

      A01375VE01
      Text in Illustration
      *a Cylinder Block Side *b Intake Side
      *c Exhaust Side - -
      Maximum warpage
      0.05 mm (0.0020 in.)

      If the warpage is greater than the maximum value, replace the cylinder head sub-assembly.

    2. A0138Q6

      Using a dye penetrant, check the combustion chamber, intake ports, exhaust ports and cylinder block surface for cracks.

  25. REMOVE CYLINDER BLOCK WATER JACKET SPACER

    A013679

    1. Remove the cylinder block water jacket spacer.

  26. REMOVE VENTILATION BAFFLE PLATE


    1. A0136P1

      Remove the 6 bolts, 2 nuts and the ventilation baffle plate.

  27. REMOVE ENGINE REAR OIL SEAL RETAINER


    1. A0135WI

      Remove the 5 bolts and the engine rear oil seal retainer.

    2. A0136JHE01
      Text in Illustration
      *1 Protective Tape

      Using a screwdriver, remove the engine rear oil seal.

      Tech Tips

      Tape the screwdriver tip before use.

  28. INSPECT CONNECTING ROD THRUST CLEARANCE


    1. A0135X9

      Using a feeler gauge, measure the thrust clearance of the connecting rod.

      Clearance
      Standard thrust
      0.1 to 0.3 mm (0.004 to 0.012 in.)
      Maximum thrust
      0.35 mm (0.0138 in.)

  29. INSPECT CONNECTING ROD OIL CLEARANCE


    1. A0138EK

      Remove the 2 bolts, connecting rod bearing cap and connecting rod bearing.

      Note

      Arrange the removed parts for each cylinder.

    2. A0136QL

      Clean the connecting rod bearing and crank pin.

    3. A0136VNE03
      Text in Illustration
      *1 Plastigage

      Lay a strip of Plastigage across the crank pin.

    4. Apply a light coat of engine oil to the threads and under the heads of the 2 bolts.

    5. Tighten the 2 bolts in several passes to the specified torque.

      Torque:
      15 N*m  { 153 kgf*cm, 11 ft.*lbf }

      Note

      Do not turn the crankshaft.

    6. A0137EZE07
      Text in Illustration
      *a Paint Mark
      *b Engine Front

      Mark the front of the 2 bolts with paint.

    7. Retighten the 2 bolts by an additional 90° as shown in the illustration.

    8. Remove the 2 bolts, then remove the connecting rod bearing cap and connecting rod bearing.

    9. A0138N8E01
      Text in Illustration
      *A Type A
      *B Type B
      *1 Plastigage
      *a Mark

      Measure the Plastigage at its widest point.

      Standard oil clearance
      0.010 to 0.036 mm (0.00039 to 0.00142 in.)
      Maximum oil clearance
      0.036 mm (0.00142 in.)

      • If the oil clearance is greater than the maximum, replace the connecting rod bearings. If necessary, inspect the crankshaft.

      • If replacing a bearing, replace it with one that has the same number as its respective connecting rod cap. Each bearing's standard thickness is indicated by mark 1, 2, or 3 on its surface.

      Standard Connecting Rod Bearing Cap Bore Diameter
      Mark Specified Condition
      1 43.000 to 43.008 mm (1.69291 to 1.69323 in.)
      2 43.008 to 43.016 mm (1.69323 to 1.69355 in.)
      3 43.016 to 43.024 mm (1.69355 to 1.69385 in.)
      Standard Connecting Rod Bearing Thickness
      Mark Specified Condition
      1 1.492 to 1.495 mm (0.05874 to 0.05886 in.)
      2 1.495 to 1.498 mm (0.05886 to 0.05898 in.)
      3 1.498 to 1.501 mm (0.05898 to 0.05909 in.)
      Standard Crankshaft Pin Diameter
      Mark Specified Condition
      1, 2, 3 39.992 to 40.000 mm (1.57445 to 1.57480 in.)

      Note

      Completely remove the Plastigage after the measurement.

      Tech Tips

      For measuring points of the connecting rod bearing cap bore diameter and connecting rod bearing thickness Click here.

    10. Perform the measurement for the other connecting rod oil clearance using the same procedure.

  30. REMOVE CONNECTING ROD SUB-ASSEMBLY


    1. A0136NL

      Push the piston, connecting rod and upper bearing through the top of the cylinder block.

      Tech Tips


      • Keep the bearing, connecting rod and cap together.

      • Arrange the piston and connecting rod for each cylinder.

  31. INSPECT CRANKSHAFT THRUST CLEARANCE


    1. A0137A8

      Using a feeler gauge, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver.

      Clearance
      Standard thrust clearance
      0.02 to 0.04 mm (0.0008 to 0.0016 in.)
      Maximum thrust clearance
      0.30 mm (0.0118 in.)

      Tech Tips


      • If the thrust clearance is greater than the maximum value, replace the thrust washer.

      • If the clearance is still greater than the maximum value even after the thrust washer is replaced, replace the crankshaft.

  32. INSPECT CRANKSHAFT OIL CLEARANCE


    1. A0138N1E01

      Loosen the 8 bolts in 2 or 3 steps and in the order shown in the illustration.

    2. Remove the 8 bolts and the 4 crankshaft bearing caps.

      Note

      Arrange the removed parts in the removed order.

      Tech Tips


      • If it is difficult to remove the crankshaft bearing cap, lightly tap it with a hammer.

      • Move the top of the crankshaft bearing cap back and forth in the axial direction.

    3. A0135Y2

      Clean the inner surfaces of the crankshaft bearing and crankshaft bearing cap and the journals of the cylinder block and crankshaft.

    4. Check these parts for excessive wear and damage.

    5. A0138GDE04
      Text in Illustration
      *1 Plastigage

      Lay a strip of Plastigage in the axial direction of the crankshaft journal.

    6. A0138N1E03

      Tighten the 8 bolts in 2 or 3 steps and in the order shown in the illustration.

      Torque:
      59 N*m  { 602 kgf*cm, 44 ft.*lbf }

      Note

      Do not turn the crankshaft.

    7. Remove the 2 bolts, then remove the crankshaft bearing cap and crankshaft bearing.

    8. A01370EE01
      Text in Illustration
      *A Type A
      *B Type B
      *1 Plastigage
      *a Mark
      *b No. 1
      *c No. 2
      *d No. 3
      *e No. 4

      Measure the Plastigage at its widest point.

      Standard oil clearance
      0.006 to 0.024 mm (0.00024 to 0.00094 in.)
      Maximum oil clearance
      0.024 mm (0.00094 in.)

      • If the oil clearance is greater than the maximum, replace the crankshaft bearing. If necessary, replace the crankshaft.

      • If replacing a bearing, select a new one with the same number. If the number of the bearing cannot be determined, calculate the correct bearing number by adding together the numbers imprinted on the cylinder block and crankshaft. Then select a new bearing with the calculated number according to the chart below. There are 4 sizes of standard bearings, marked "2", "3", "4" and "5" accordingly.

      • EXAMPLE: Cylinder block mark "2" + Crankshaft mark "2" = Use bearing mark "4"

      Standard Cylinder Block Journal Bore Diameter
      Mark Specified Condition
      1 48.000 to 48.006 (1.88976 to 1.89000)
      2 48.006 to 48.012 (1.89000 to 1.89023)
      3 48.012 to 48.018 (1.89023 to 1.890047)
      Standard Crankshaft Journal Diameter
      Mark Specified Condition
      1 43.994 to 44.000 (1.73204 to 1.73228)
      2 43.988 to 43.994 (1.73171 to 1.73204)
      Standard Bearing Center Wall Thickness
      Mark Specified Condition
      2 1.994 to 1.997 (0.07850 to 0.07862)
      3 1.997 to 2.000 (0.07862 to 0.07874)
      4 2.000 to 2.003 (0.07874 to 0.07886)
      5 2.003 to 2.006 (0.07886 to 0.07898)

      Note

      Completely remove the Plastigage after the measurement.

  33. REMOVE PISTON RING SET


    1. A0135WH

      Using a piston ring expander, remove the No. 1 compression ring, No. 2 compression ring and oil ring.

      Note

      Do not reuse any piston rings.

  34. REMOVE W/ PIN PISTON SUB-ASSEMBLY


    1. A0136L4E01

      Using SST, press out the piston pin from the piston. Remove the piston.

      SST
      09221-25026   ( 09221-00021, 09221-00030, 09221-00130, 09221-00141, 09221-00150 )

      Tech Tips


      • The piston and pin are a matched set.

      • Arrange the pistons, pins, rings, connecting rods and bearings in correct order.