ENGINE UNIT DISASSEMBLY


  1. REMOVE ENGINE COVER JOINT


    1. A01EJ2D

      Remove the 3 joints.

  2. REMOVE SPARK PLUG


    1. A01EJOV

      Using a spark plug wrench, remove the 4 spark plugs.

  3. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Intake Side)


    1. A01EIXE

      Disconnect the oil control valve connector.

    2. Remove the bolt and oil control valve.

    3. A01EMPGE06
      Text in Illustration
      *1 O-ring

      Remove the O-ring from the oil control valve.

  4. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Exhaust Side)


    1. A01EKZV

      Disconnect the oil control valve connector.

    2. Remove the bolt and oil control valve.

    3. A01EMPGE06
      Text in Illustration
      *1 O-ring

      Remove the O-ring from the oil control valve.

  5. REMOVE CAMSHAFT POSITION SENSOR (for Intake Side)

    A01EJWD

    1. Disconnect the sensor connector.

    2. Remove the bolt and sensor.

  6. REMOVE CAMSHAFT POSITION SENSOR (for Exhaust Side)

    A01EJB5

    1. Disconnect the sensor connector.

    2. Remove the bolt and sensor.

  7. REMOVE OIL FILLER CAP SUB-ASSEMBLY


    1. Remove the oil filler cap from the cylinder head.

    2. Remove the gasket from the oil filler cap.

  8. REMOVE CRANKSHAFT POSITION SENSOR

    A01EJZL

    1. Disconnect the sensor connector.

    2. Remove the bolt and sensor.

  9. REMOVE VENTILATION VALVE SUB-ASSEMBLY


    1. A01EK5M

      Disconnect the No. 2 ventilation hose from the ventilation valve.

    2. A01EL3ZE02
      Text in Illustration
      *1 19 mm Deep Socket Wrench

      Using a 19 mm deep socket wrench, remove the ventilation valve.

  10. REMOVE VENTILATION CASE SUB-ASSEMBLY


    1. A01EL4D

      Remove the 8 bolts and 2 nuts.

    2. A01EJZH

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

      Tech Tips

      Tape the screwdriver tip before use.

      Note

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

  11. REMOVE SEPARATOR CASE


    1. A01EJ7Q

      Remove the 2 bolts, separator case and gasket.

  12. REMOVE NO. 1 WATER BY-PASS PIPE


    1. A01EKHJ

      Remove the bolt, 2 nuts, water by-pass pipe and gasket.

  13. REMOVE WATER INLET


    1. A01EL0B

      Remove the 2 nuts and water inlet.

  14. REMOVE THERMOSTAT


    1. Remove the thermostat.

    2. Remove the gasket from the thermostat.

  15. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY


    1. A01EM6M

      Remove the bolt and V-ribbed belt tensioner.

  16. REMOVE WATER PUMP ASSEMBLY


    1. A01EKU5

      Remove the 7 bolts, water pump and water pump gasket.

  17. REMOVE OIL COOLER ASSEMBLY (w/ Oil Cooler)


    1. A01EL7IE01

      Remove the nut, union bolt, seal washer and oil cooler assembly.

    2. Remove the 3 gaskets from the oil cooler assembly.

  18. REMOVE INLET WATER HOUSING


    1. A01EKO0

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

  19. REMOVE CRANKSHAFT PULLEY


    1. A01EM6PE01

      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. A01EJVME01

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

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

      Tech Tips

      Apply a lubricant to the threads and end of SST.

  20. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A01EM9P

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

    2. A01EM0R

      Remove the 3 gaskets from the camshaft bearing caps.

  21. REMOVE SPARK PLUG TUBE GASKET


    1. A01EM72

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

      Note

      Be careful not to damage the cylinder head cover.

      Tech Tips

      Tape the screwdriver tip before use.

  22. REMOVE ENGINE MOUNTING BRACKET RH


    1. A01EMRJ

      Remove the 5 bolts and engine mounting bracket RH.

  23. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY


    1. A01EM0Y

      Remove the 17 bolts and 2 nuts.

    2. A01EK8U

      Remove the timing chain cover sub-assembly by prying between the timing chain cover sub-assembly and cylinder head, camshaft housing, cylinder block and stiffening crankcase with a screwdriver as shown in the illustration.

      Note

      Be careful not to damage the contact surfaces of the cylinder head, camshaft housing, cylinder block, stiffening crankcase and timing chain cover sub-assembly.

      Tech Tips

      Tape the screwdriver tip before use.

    3. A01EMIS

      Remove the 2 oil pump gaskets and oil hole cover gasket from the stiffening crankcase.

  24. REMOVE TIMING CHAIN COVER TIGHT PLUG


    1. A01EIZZ

      Using a 14 mm hexagon wrench, remove the plug and gasket.

  25. REMOVE TIMING CHAIN COVER PLATE


    1. A01EMPJ

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

  26. REMOVE TIMING CHAIN COVER OIL SEAL


    1. A01EMCRE01

      Using a screwdriver and wooden block, pry out the timing chain cover oil seal.

      Note

      Do not damage the surface of the timing chain cover oil seal press fit hole.

      Tech Tips

      Tape the screwdriver tip before use.

  27. SET NO. 1 CYLINDER TO TDC/COMPRESSION


    1. Temporarily install the crankshaft pulley bolt.

      A01EKWBE01

      Tech Tips

      "A" is not a timing mark.

    2. Rotate the crankshaft clockwise so that the timing marks on the crankshaft timing gear and camshaft timing gears are as shown in the illustration.

      Tech Tips

      If the timing marks do not align, rotate the crankshaft clockwise again and align the timing marks.

    3. Remove the crankshaft pulley bolt.

  28. REMOVE TIMING CHAIN GUIDE


    1. A01ELJY

      Remove the bolt and timing chain guide.

  29. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY


    1. A01EM07E03
      Text in Illustration
      *1 Stopper Plate
      *2 Plunger

      Allow the plunger to extend slightly, and then rotate the stopper plate counterclockwise to release the lock. Once the lock is released, push the plunger into the tensioner.

    2. A01EJD1E03
      Text in Illustration
      *1 Pin

      Move the stopper plate clockwise to set the lock, and insert a pin into the stopper plate hole.

    3. A01ELLA

      Remove the 2 bolts, chain tensioner and gasket.

  30. REMOVE CHAIN TENSIONER SLIPPER


    1. A01EKD5

      Remove the bolt and chain tensioner slipper.

  31. REMOVE CHAIN SUB-ASSEMBLY


    1. Remove the chain sub-assembly.

  32. REMOVE NO. 1 CHAIN VIBRATION DAMPER


    1. A01EM6Y

      Remove the 2 bolts and chain vibration damper.

  33. REMOVE CRANKSHAFT TIMING SPROCKET


    1. A01ELAKE01

      Remove the crankshaft timing sprocket from the crankshaft.

  34. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY


    1. A01EMLK

      Hold the hexagonal portion of the camshaft with a wrench and remove the bolt and camshaft timing gear.

      Note


      • Be careful not to damage the cylinder head or spark plug tube with the wrench.

      • Do not disassemble the camshaft timing gear.

  35. REMOVE CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY


    1. A01EMPU

      Hold the hexagonal portion of the camshaft with a wrench and remove the bolt and camshaft timing exhaust gear.

      Note


      • Be careful not to damage the cylinder head or spark plug tube with the wrench.

      • Do not disassemble the camshaft timing exhaust gear.

  36. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY


    1. A01EMJOE01

      Uniformly loosen and remove the 20 bearing cap bolts in the sequence shown in the illustration.

    2. A01EKFN

      Remove the camshaft housing by prying between the cylinder head and camshaft housing with a screwdriver.

      Tech Tips

      Tape the screwdriver tip before use.

      Note

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

  37. REMOVE CAMSHAFT BEARING CAP


    1. A01ELKUE01

      Remove the 11 bearing cap bolts in the sequence shown in the illustration.

    2. Remove the 5 bearing caps.

      Tech Tips

      Arrange the removed parts in the correct order.

  38. REMOVE OIL CONTROL VALVE FILTER


    1. A01EM6ZE01

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

  39. REMOVE CAMSHAFT


    1. Remove the No. 1 and No. 2 camshafts.

  40. REMOVE NO. 1 CAMSHAFT BEARING


    1. A01EJMYE01

      Remove the No. 1 camshaft bearing.

  41. REMOVE NO. 2 CAMSHAFT BEARING


    1. A01EJ22E01

      Remove the No. 2 camshaft bearing.

  42. REMOVE CAMSHAFT HOUSING STUD BOLT

    Note

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

  43. REMOVE CAMSHAFT BEARING CAP SETTING RING PIN

    Note

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

  44. REMOVE CAMSHAFT HOUSING STRAIGHT PIN

    Note

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

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


    1. Remove the 16 valve rocker arms from the cylinder head.

      Tech Tips

      Arrange the removed parts in the correct order.

  46. REMOVE VALVE LASH ADJUSTER ASSEMBLY


    1. Remove the 16 valve lash adjusters from the cylinder head.

      Tech Tips

      Arrange the removed parts in the correct order.

  47. REMOVE VALVE STEM CAP


    1. Remove the 16 valve stem caps from the cylinder head.

      Tech Tips

      Arrange the removed parts in the correct order.

  48. REMOVE CYLINDER HEAD SUB-ASSEMBLY


    1. A01EJ20E01

      Using a 10 mm bi-hexagon wrench, uniformly loosen the 10 bolts in the sequence shown in the illustration. Remove the 10 cylinder head bolts and plate washers.

      Tech Tips

      Be sure to keep the removed parts separate for each installation position.

      Note


      • Be careful not to drop washers into the cylinder head.

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

    2. Remove the cylinder head.

  49. REMOVE CYLINDER HEAD GASKET


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

  50. REMOVE CYLINDER BLOCK WATER JACKET SPACER


    1. A01EL8H

      Remove the cylinder block water jacket spacer from the cylinder block.

      Note

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

  51. REMOVE OIL FILTER CAP ASSEMBLY


    1. A01EJGOE09
      Text in Illustration
      *1 Pipe
      *a Hose

      Connect a hose with an inside diameter of 15 mm (0.591 in.) to the pipe.

    2. A01EJJD

      Remove the oil filter drain plug from the oil filter cap assembly.

    3. A01EIUJE07
      Text in Illustration
      *1 Oil Filter Cap Assembly
      *2 O-ring
      *3 Pipe
      *a Valve

      Install the pipe with the hose into the oil filter cap assembly.

      Note

      If the O-ring is removed with the oil filter drain plug, install the O-ring together with the pipe.

      Tech Tips

      Use a container to catch the draining oil.

    4. A01EJT7

      Check that the engine oil is drained from the oil filter cap assembly. Then disconnect the pipe as shown in the illustration and remove the O-ring.

    5. A01EL7YE02
      Text in Illustration
      *1 Oil Filter Bracket Clip

      Using SST, remove the oil filter cap assembly.

      SST
      09228-06501

      Note

      Do not remove the oil filter bracket clip.

    6. A01EIZ7E01
      Text in Illustration
      *1 Oil Filter Element
      *2 O-ring

      Remove the oil filter element and O-ring from the oil filter cap assembly.

      Note

      Do not use any tools to remove the O-ring to prevent damage to the oil filter cap assembly. Be sure to remove it by hand.

  52. REMOVE OIL PAN SUB-ASSEMBLY


    1. A01EMFR

      Remove the 11 bolts and 2 nuts.

    2. A01EJ46

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

      Note


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

      • Be careful not to damage the stiffening crankcase flange.

  53. REMOVE OIL STRAINER SUB-ASSEMBLY


    1. A01EKYT

      Remove the 3 bolts, oil strainer and gasket.

  54. REMOVE NO. 1 OIL PAN BAFFLE PLATE


    1. A01EMRH

      Remove the 5 bolts and oil pan baffle plate.

  55. INSPECT CRANKSHAFT BACKLASH


    1. A01ELM9

      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.

  56. REMOVE ENGINE BALANCER ASSEMBLY


    1. A01EKUU

      Remove the 7 bolts and engine balancer.

      Note

      Do not disassemble the engine balancer.

  57. INSPECT BALANCE SHAFT THRUST CLEARANCE


    1. A01EM3QE02
      Text in Illustration
      *1 No. 1 Balance Shaft

      Using a dial indicator, measure the thrust clearance while moving the No. 1 balance shaft back and forth.

      Standard thrust clearance
      0.05 to 0.09 mm (0.00197 to 0.00354 in.)
      Maximum thrust clearance
      0.09 mm (0.00354 in.)

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

    2. A01EL7OE02
      Text in Illustration
      *1 No. 2 Balance Shaft

      Using a dial indicator, measure the thrust clearance while moving the No. 2 balance shaft back and forth.

      Standard thrust clearance
      0.05 to 0.09 mm (0.00197 to 0.00354 in.)
      Maximum thrust clearance
      0.09 mm (0.00354 in.)

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

  58. REMOVE STIFFENING CRANKCASE ASSEMBLY


    1. A01ELSL

      Remove the 7 bolts.

    2. A01EJX4E01

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

      Tech Tips

      Tape the screwdriver tip before use.

      Note

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

  59. REMOVE STIFFENING CRANKCASE STUD BOLT

    Note

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

  60. REMOVE STIFFENING CRANKCASE RING PIN

    Note

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

  61. REMOVE REAR ENGINE OIL SEAL


    1. A01EJO4E01

      Remove the rear engine oil seal from the cylinder block.