ENGINE UNIT DISASSEMBLY

REMOVE ENGINE COVER JOINT
1. Remove the 3 joints.
REMOVE SPARK PLUG
1. Using a spark plug wrench, remove the 4 spark plugs.
REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY
1. Camshaft timing oil control valve assembly (for exhaust side)
  1. Disconnect the oil control valve connector.
  2. Remove the bolt and oil control valve.
  3. Text in Illustration
    
    *1 O-ring
    
    Remove the O-ring from the oil control valve.
2. Camshaft timing oil control valve assembly (for intake side)
  1. Disconnect the oil control valve connector.
  2. Remove the bolt and oil control valve.
  3. Text in Illustration
    
    *1 O-ring
    
    Remove the O-ring from the oil control valve.
REMOVE CAMSHAFT POSITION SENSOR
1. Camshaft position sensor (for Exhaust Side)
  1. Disconnect the sensor connector.
  2. Remove the bolt and sensor.
2. Camshaft position sensor (for Intake Side)
  1. Disconnect the sensor connector.
  2. Remove the bolt and sensor.
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.
REMOVE CRANKSHAFT POSITION SENSOR
1. Disconnect the sensor connector.
2. Remove the bolt and sensor.
REMOVE VENTILATION VALVE SUB-ASSEMBLY
1. Disconnect the No. 2 ventilation hose from the ventilation valve sub-assembly.
2. Text in Illustration
  
  *1 19 mm Deep Socket Wrench
  
  Using a 19 mm deep socket wrench, remove the ventilation valve sub-assembly.
REMOVE VENTILATION CASE SUB-ASSEMBLY
1. Remove the 8 bolts and 2 nuts.
2. 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.
REMOVE SEPARATOR CASE
1. Remove the 2 bolts, separator case and gasket.
REMOVE NO. 1 WATER BY-PASS PIPE
1. Remove the bolt, 2 nuts, water by-pass pipe and gasket.
REMOVE WATER INLET
1. Remove the 2 nuts and water inlet.
REMOVE THERMOSTAT
1. Remove the thermostat.
2. Remove the gasket from the thermostat.
REMOVE V-RIBBED BELT TENSIONER ASSEMBLY
1. Remove the bolt and V-ribbed belt tensioner.
REMOVE ENGINE WATER PUMP ASSEMBLY
1. Remove the 7 bolts, engine water pump and gasket.
REMOVE WATER INLET HOUSING
1. Remove the 4 bolts, nut, inlet water housing and gasket.

Text in Illustration
*1	O-ring

Text in Illustration
*1	O-ring

Text in Illustration
*1	19 mm Deep Socket Wrench

REMOVE CRANKSHAFT PULLEY

Text in Illustration

*a Hold

*b Turn

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

Part number of installation bolt for SST (crankshaft pulley holding tool): 91551-80650 (quantity: 2)

Text in Illustration
*a	Hold
*b	Turn

Text in Illustration
*1	Pulley Bolt
*a	Hold
*b	Turn

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.

REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY
1. Remove the 16 bolts, 3 seal washers, cylinder head cover and gasket.
2. Remove the 3 gaskets from the camshaft bearing caps.
REMOVE SPARK PLUG TUBE GASKET
1. 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.
REMOVE ENGINE MOUNTING BRACKET RH
1. Remove the 5 bolts and engine mounting bracket RH.
REMOVE TIMING CHAIN COVER SUB-ASSEMBLY
1. Remove the 17 bolts and 2 nuts.
2. Remove the timing chain cover by prying between the timing chain cover 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 or chain cover.
  
  Tech Tips
  
  Tape the screwdriver tip before use.
3. Remove the 3 gaskets from the stiffening crankcase.
REMOVE TIMING CHAIN COVER TIGHT PLUG
1. Using a 14 mm hexagon wrench, remove the plug and gasket.
REMOVE TIMING CHAIN COVER PLATE
1. Remove the 4 bolts, timing chain cover plate and gasket.
REMOVE TIMING CHAIN COVER OIL SEAL
1. Text in Illustration
  
  *1 Wooden Block
  
  Using a screwdriver and wooden block, pry out the oil seal.
  
  Note
  
  Do not damage the surface of the oil seal press fit hole.
  
  Tech Tips
  
  Tape the screwdriver tip before use.

Text in Illustration
*1	Wooden Block

SET NO. 1 CYLINDER TO TDC/COMPRESSION

Temporarily install the crankshaft pulley bolt.

Text in Illustration
*a	Approximately 7°	*b	Approximately 32°
*c	Timing Mark	*d	Key

Tech Tips

"A" is not a timing mark.

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.
Remove the crankshaft pulley bolt.

REMOVE TIMING CHAIN GUIDE
1. Remove the bolt and timing chain guide.
REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY
1. 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. Text in Illustration
  
  *1 Pin
  
  Move the stopper plate clockwise to set the lock, and insert a pin into the stopper plate hole.
3. Remove the 2 bolts, chain tensioner and gasket.
REMOVE CHAIN TENSIONER SLIPPER
1. Remove the bolt and chain tensioner slipper.
REMOVE CHAIN SUB-ASSEMBLY
1. Remove the chain sub-assembly.
REMOVE NO. 1 CHAIN VIBRATION DAMPER
1. Remove the 2 bolts and chain vibration damper.
REMOVE CRANKSHAFT TIMING SPROCKET
1. Remove the crankshaft timing sprocket from the crankshaft.
REMOVE CAMSHAFT TIMING GEAR ASSEMBLY
1. Text in Illustration
  
  *a Hold
  
  *b Turn
  
  Hold the hexagonal portion of the camshaft with a wrench and remove the bolt and camshaft timing gear assembly.
  Note
  - Be careful not to damage the cylinder head sub-assembly or spark plug tube with the wrench.
  - Do not disassemble the camshaft timing gear assembly.
REMOVE CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY
1. Text in Illustration
  
  *a Hold
  
  *b Turn
  
  Hold the hexagonal portion of the camshaft with a wrench and remove the bolt and camshaft timing exhaust gear assembly.
  Note
  - Be careful not to damage the cylinder head sub-assembly or spark plug tube with the wrench.
  - Do not disassemble the camshaft timing exhaust gear assembly.
REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY
1. Uniformly loosen and remove the 20 bearing cap bolts in the sequence shown in the illustration.
2. Remove the camshaft housing by prying between the cylinder head sub-assembly and camshaft housing sub-assembly 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 sub-assembly.
REMOVE CAMSHAFT BEARING CAP
1. 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.
REMOVE OIL CONTROL VALVE FILTER
1. Remove the oil control valve filter from the No. 1 camshaft bearing cap.
REMOVE CAMSHAFT
1. Remove the camshaft and No. 2 camshaft.
REMOVE NO. 1 CAMSHAFT BEARING
1. Remove the No. 1 camshaft bearing.
REMOVE NO. 2 CAMSHAFT BEARING
1. Remove the No. 2 camshaft bearing.
REMOVE CAMSHAFT HOUSING STUD BOLT

Note

If a stud bolt is deformed or its threads are damaged, replace it.
REMOVE CAMSHAFT BEARING CAP SETTING RING PIN

Note

It is not necessary to remove the ring pin unless it is being replaced.
REMOVE CAMSHAFT HOUSING STRAIGHT PIN

Note

It is not necessary to remove the straight pin unless it is being replaced.
REMOVE NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY
1. Remove the 16 valve rocker arms from the cylinder head sub-assembly.
  
  Tech Tips
  
  Arrange the removed parts in the correct order.
REMOVE VALVE LASH ADJUSTER ASSEMBLY
1. Remove the 16 valve lash adjusters from the cylinder head sub-assembly.
  
  Tech Tips
  
  Arrange the removed parts in the correct order.
REMOVE VALVE STEM CAP
1. Remove the 16 valve stem caps from the cylinder head sub-assembly.
  
  Tech Tips
  
  Arrange the removed parts in the correct order.
REMOVE CYLINDER HEAD SUB-ASSEMBLY
1. 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 sub-assembly.
  
  Head warpage or cracking could result from removing bolts in the incorrect order.
2. Remove the cylinder head sub-assembly.
REMOVE CYLINDER HEAD GASKET
1. Remove the cylinder head gasket from the cylinder block.
REMOVE CYLINDER BLOCK WATER JACKET SPACER
1. 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.

Text in Illustration
*1	Stopper Plate
*2	Plunger

Text in Illustration
*1	Pin

Text in Illustration
*a	Hold
*b	Turn

Text in Illustration
*a	Hold
*b	Turn

REMOVE OIL FILTER CAP ASSEMBLY

Text in Illustration

*1 Pipe

*2 Hose

Connect a hose with an inside diameter of 15 mm (0.591 in.) to the pipe.
Remove the oil filter drain plug from the oil filter cap.

Text in Illustration
*1	Pipe
*2	Hose

Text in Illustration
*1	Valve
*2	Cap
*3	O-ring
*4	Pipe

Install the pipe to the oil filter cap.

Note

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

Tech Tips

Use a container to catch the draining oil.

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

*1 Oil Filter Bracket Clip

Using SST, remove the oil filter cap.

SST

09228-06501

Note

Do not remove the oil filter bracket clip.

Text in Illustration
*1	Oil Filter Bracket Clip

Text in Illustration
*1	Oil Filter Element
*2	Oil Filter Cap
*3	O-ring

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

Note

Be sure to remove the O-ring by hand, without using any tools, to prevent damage to the O-ring groove.

REMOVE OIL PAN SUB-ASSEMBLY
1. Text in Illustration
  
  *1 Nut
  
  Remove the 11 bolts and 2 nuts.
2. 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.
REMOVE OIL STRAINER SUB-ASSEMBLY
1. Remove the 3 bolts, oil strainer and gasket.
REMOVE NO. 1 OIL PAN BAFFLE PLATE
1. Remove the 5 bolts and oil pan baffle plate.
INSPECT CRANKSHAFT BACKLASH
1. 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.
REMOVE ENGINE BALANCER ASSEMBLY
1. Remove the 7 bolts and engine balancer.
  
  Note
  
  Do not disassemble the engine balancer.
INSPECT BALANCE SHAFT THRUST CLEARANCE
1. 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.
REMOVE STIFFENING CRANKCASE ASSEMBLY
1. Remove the 7 bolts.
2. Text in Illustration
  
  *a LH Side:
  
  *b RH Side:
  
  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.
REMOVE STIFFENING CRANKCASE STUD BOLT

Note

If a stud bolt is deformed or its threads are damaged, replace it.
REMOVE STIFFENING CRANKCASE RING PIN

Note

It is not necessary to remove the ring pin unless it is being replaced.
REMOVE REAR ENGINE OIL SEAL
1. Remove the rear engine oil seal from the cylinder block.

Text in Illustration
*a	LH Side:
*b	RH Side: