ENGINE UNIT DISASSEMBLY


  1. REMOVE WATER PUMP ASSEMBLY


    1. A0136A4

      Remove the 7 bolts and water pump.

  2. REMOVE CAMSHAFT DRIVE PULLEY


    1. A0137N4

      Using SST, remove the bolt and camshaft drive pulley.

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

  3. REMOVE INJECTION PUMP BRACKET


    1. A0137T1

      Remove the 3 bolts and injection pump bracket.

  4. REMOVE TIMING BELT IDLER SUB-ASSEMBLY


    1. A0137ZH

      Remove the nut and timing belt idler sub-assembly.

  5. REMOVE CAMSHAFT BEARING CAP UPPER HOUSING


    1. A0138JQE03

      Using several steps, uniformly loosen and remove the camshaft bearing cap upper housing bolts in the order shown in the illustration.

  6. REMOVE CAMSHAFT SUB-ASSEMBLY


    1. Remove the camshaft and oil seal.

  7. REMOVE CAMSHAFT BEARING CAP LOWER HOUSING


    1. A0136LXE02

      Using several steps, uniformly loosen and remove the camshaft bearing cap lower housing bolts in the order shown in the illustration.

    2. Remove the 5 O-rings, 8 valve rocker arms and 8 valve lash adjusters.

  8. REMOVE CYLINDER HEAD SUB-ASSEMBLY


    1. A013909E01

      Using a ''torx'' socket wrench (E14), uniformly loosen and remove the cylinder head bolts in the order shown in the illustration.

    2. A0138SV

      Remove the cylinder head sub-assembly and cylinder head gasket from the cylinder block assembly.

      Tech Tips

      Pry between the cylinder head and cylinder block with a screwdriver to lift off the cylinder head.

      Note

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

  9. CLEAN CYLINDER HEAD SUB-ASSEMBLY


    1. A0137TR

      Using a scraper, clean the contact surface of the cylinder head.

  10. CLEAN CYLINDER BLOCK SUB-ASSEMBLY


    1. A0137Z9

      Using a scraper, clean the contact surface of the cylinder block.

  11. REMOVE VALVE


    1. Remove intake valve.


      1. A0137EG

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

        SST
        09202-70020   ( 09202-00020, 09202-01010, 09202-01020, 90154-80004 )

    2. Remove exhaust valve.


      1. A01393C

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

        SST
        09202-70020   ( 09202-00020, 09202-01010, 09202-01020, 90154-80004 )

  12. REMOVE VALVE STEM OIL SEAL


    1. A013935

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

  13. REMOVE VALVE GUIDE BUSH


    1. A01386V

      Heat the cylinder head to 80 to 100°C (176 to 212°F).

    2. Using SST and a hammer, tap out the valve guide bushes.

      SST
      09201-10000   ( 09201-01050 )

  14. REMOVE OIL PRESSURE REGULATOR


    1. A0137ZD

      Remove the oil pressure regulator.

  15. REMOVE OIL CHECK VALVE


    1. A0138AW

      Remove the oil check valve.

  16. INSPECT CYLINDER HEAD SUB-ASSEMBLY


    1. Clean the surface to be checked.

    2. A0137DH

      Using a straight edge and feeler gauge, measure the warpage on the contact surface.

      Maximum warpage
      0.05 mm (0.0020 in.)

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

  17. REMOVE OIL PAN SUB-ASSEMBLY


    1. A0135XE

      Remove the 2 nuts and 15 bolts.

    2. A0135Z6

      Using an oil pan cutter, remove the oil pan sub-assembly from the cylinder block assembly.

      SST
      09032-00100

  18. REMOVE OIL STRAINER SUB-ASSEMBLY


    1. A0136C0

      Using a hexagon socket wrench, remove the 3 bolts, oil strainer sub-assembly and gaskets.

  19. REMOVE OIL PUMP ASSEMBLY


    1. A0136EK

      Remove the 8 bolts and oil pump assembly.

  20. REMOVE CRANKSHAFT BEARING CAP HOUSING


    1. A01366U

      Using a screwdriver, remove the 2 crankshaft bearing cap housing bolt covers.

    2. A0136II

      Remove the 26 bolts, crankshaft bearing cap housing and oil seal.

    3. Remove the crankshaft lower bearings.

  21. REMOVE CONNECTING ROD BEARING CAP


    1. A0138NT

      Using a ''torx'' socket wrench (E10), remove the 2 bolts and connecting rod cap.

    2. Remove the connecting rod bearing from the connecting rod cap.

  22. REMOVE CONNECTING ROD SUB-ASSEMBLY


    1. A0136IN

      Push the connecting rod sub-assembly and remove the connecting rod and piston through the top of the cylinder block.

      Tech Tips

      Arrange the connecting rod sub-assembly for each cylinder.

    2. Remove the connecting rod upper bearing.

  23. INSPECT CRANKSHAFT


    1. A0137QL

      Using a dial indicator, measure the thrust clearance while moving the crankshaft back and forth.

      Standard clearance
      0.07 to 0.32 mm (0.0028 to 0.0126 in.)

  24. REMOVE CRANKSHAFT


    1. Remove the crankshaft.

    2. Remove the crankshaft upper bearing.

  25. REMOVE OIL NOZZLE SUB-ASSEMBLY


    1. A0136EP

      Using a hexagon socket wrench, remove the 4 bolts and 4 oil nozzles.

  26. REMOVE PISTON RING SET


    1. A0136K2

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

  27. REMOVE W/ PIN PISTON SUB-ASSEMBLY


    1. A0137BK

      Using a screwdriver, pry off the snap rings from the piston.

    2. Remove the piston pin and connecting rod.