ENGINE UNIT DISASSEMBLY


  1. REMOVE VACUUM PUMP ASSEMBLY


    1. B000HXI

      Remove the 4 bolts and vacuum pump assembly.

    2. B000GY1E01
      Text in Illustration
      *1 No. 2 O-ring
      *2 No. 3 O-ring

      Remove the No. 2 O-ring and No. 3 O-ring from the vacuum pump assembly.

  2. REMOVE KNOCK CONTROL SENSOR


    1. B000IW2

      Disconnect the knock control sensor connector.

    2. Remove the bolt and knock control sensor from the cylinder block sub-assembly.

      Note

      If the knock control sensor has been struck or dropped, replace it.

  3. REMOVE OIL PRESSURE SENDER GAUGE ASSEMBLY


    1. Disconnect the oil pressure sender gauge assembly connector.

    2. B000JII

      Using a 27 mm deep socket wrench, remove the oil pressure sender gauge assembly.

  4. REMOVE ENGINE COOLANT TEMPERATURE SENSOR


    1. B000KW6

      Disconnect the engine coolant temperature sensor connector.

    2. B000MQ8E01
      Text in Illustration
      *1 Engine Coolant Temperature Sensor
      *2 Gasket

      Using SST, remove the engine coolant temperature sensor from the cylinder head sub-assembly.

      SST
      09817-33191

      Note

      If the engine coolant temperature sensor has been struck or dropped, replace it.

    3. Remove the gasket from the engine coolant temperature sensor.

  5. REMOVE ENGINE COVER JOINT


    1. B000GXI

      Remove the 2 engine cover joints.

  6. REMOVE SPARK PLUG


    1. B000K7L

      Remove the 4 spark plugs from the cylinder head sub-assembly.

      Note

      If a spark plug has been struck or dropped, replace it.

      Tech Tips

      Arrange the removed parts in the correct order.

  7. REMOVE OIL FILLER CAP SUB-ASSEMBLY


    1. Remove the oil filler cap sub-assembly from the cylinder head cover sub-assembly.

    2. Remove the gasket from the oil filler cap sub-assembly.

  8. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY


    1. B000M90

      Disconnect the camshaft timing oil control valve assembly connector.

    2. Remove the bolt and camshaft timing oil control valve assembly from the cylinder head cover sub-assembly.

      Note


      • Do not allow foreign matter to contact the oil seal face of the camshaft timing oil control valve assembly (connecting surface with the cylinder head cover sub-assembly).

      • If the camshaft timing oil control valve assembly has been struck or dropped, replace it.

    3. B000KDXE02
      Text in Illustration
      *1 O-ring

      Remove the O-ring from the camshaft timing oil control valve assembly.

  9. REMOVE CAMSHAFT POSITION SENSOR (for Intake Side)


    1. B000IH9

      Disconnect the camshaft position sensor connector.

    2. Remove the bolt and camshaft position sensor from the cylinder head cover sub-assembly.

      Note

      If the camshaft position sensor has been struck or dropped, replace it.

  10. REMOVE CAMSHAFT POSITION SENSOR (for Exhaust Side)


    1. B000J1Z

      Disconnect the camshaft position sensor connector.

    2. Remove the bolt and camshaft position sensor from the cylinder head cover sub-assembly.

      Note

      If the camshaft position sensor has been struck or dropped, replace it.

  11. REMOVE PCV VALVE (VENTILATION VALVE SUB-ASSEMBLY)


    1. B000JFN

      Using a 19 mm deep socket wrench, remove the PCV valve (ventilation valve sub-assembly) from the cylinder head cover sub-assembly.

  12. REMOVE NO. 1 VENTILATION CASE


    1. B000H5F

      Remove the 8 bolts and 2 nuts.

      Text in Illustration
      B000K70 Bolt
      B000IB9 Nut
    2. B000NFN

      Remove the No. 1 ventilation case by prying between the No. 1 ventilation case and cylinder block sub-assembly with a screwdriver.

      Note

      Be careful not to damage the contact surfaces of the cylinder block sub-assembly and No. 1 ventilation case.

      Tech Tips

      Tape the screwdriver tip before use.

  13. REMOVE CRANKSHAFT POSITION SENSOR


    1. B000IR2

      Disconnect the crankshaft position sensor connector.

    2. Remove the bolt and crankshaft position sensor from the timing chain cover sub-assembly.

      Note

      If the crankshaft position sensor has been struck or dropped, replace it.

  14. REMOVE CRANKSHAFT PULLEY


    1. B000MO0E01
      Text in Illustration
      *a Hold
      *b Turn

      Using SST, hold the crankshaft pulley and loosen the crankshaft pulley set bolt. Further loosen the crankshaft pulley set 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)

    2. B000N3YE04
      Text in Illustration
      *1 Crankshaft Pulley Set Bolt
      *a Hold
      *b Turn

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

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

      Tech Tips

      Apply lubricant to the threads and end of SST.

  15. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY


    1. B000HPN

      Remove the 17 bolts, 3 seal washers, cylinder head cover sub-assembly and cylinder head cover gasket.

      Text in Illustration
      B000K70 Bolt
      B000IB9 Bolt with Seal Washer
    2. B000JJVE01
      Text in Illustration
      *1 Camshaft Bearing Cap Oil Hole Gasket
      *a Gasket

      Remove the camshaft bearing cap oil hole gasket from the No. 1 camshaft bearing cap.

    3. Remove the gasket from the No. 2 camshaft bearing cap.

  16. REMOVE CASE SEPARATOR


    1. B000LHG

      Remove the 2 bolts and case separator from the cylinder head cover case sub-assembly.

    2. B000IB8

      Remove the oil separator gasket from the case separator.

    3. B000IWGE01
      Text in Illustration
      *a O-ring

      Remove the O-ring from the case separator.

  17. REMOVE SPARK PLUG TUBE GASKET


    1. B000HGPE01
      Text in Illustration
      *a Protective Tape

      Using a screwdriver, pry out the 4 spark plug tube gaskets from the cylinder head cover sub-assembly.

      Note

      Be careful not to damage the cylinder head cover sub-assembly.

      Tech Tips

      Tape the screwdriver tip before use.

  18. REMOVE CAMSHAFT TIMING OIL CONTROL SOLENOID ASSEMBLY


    1. B000HM8

      Disconnect the camshaft timing oil control solenoid assembly connector.

    2. Remove the 2 bolts and camshaft timing oil control solenoid assembly from the timing chain cover sub-assembly.

      Note

      If the camshaft timing oil control solenoid assembly has been struck or dropped, replace it.

    3. B000JQG

      Remove the O-ring from the camshaft timing oil control solenoid assembly.

      Note


      • If the O-ring comes off in the timing chain cover sub-assembly, make sure to remove it.

      • Do not drop the O-ring into the timing chain cover sub-assembly.

  19. REMOVE TIMING CHAIN COVER PLATE


    1. B000HSL

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

  20. REMOVE ENGINE MOUNTING BRACKET RH


    1. B000HZQ

      Remove the 5 bolts and engine mounting bracket RH.

  21. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY


    1. B000IDS

      Remove the 17 bolts and 2 nuts.

      Text in Illustration
      B000K70 Bolt
      B000IB9 Nut

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

      B000MOSE01
      Text in Illustration
      *a Protective Tape - -

      Note

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

      Tech Tips

      Tape the screwdriver tip before use.

    3. B000JJSE01
      Text in Illustration
      *1 Oil Pump Gasket
      *2 Oil Hole Cover Gasket

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

  22. REMOVE TIMING CHAIN COVER OIL SEAL


    1. B000JGYE05
      Text in Illustration
      *a Protective Tape
      *b Wooden Block

      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.

  23. SET NO. 1 CYLINDER TO TDC/COMPRESSION


    1. Temporarily install the crankshaft pulley set bolt.

      B000MMVE01
      Text in Illustration
      *1 Crankshaft Pulley Key - -
      *a Approximately 7° *b Approximately 32°
      *c Timing Mark - -

    2. Rotate the crankshaft clockwise and align the crankshaft pulley key as shown in the illustration.

    3. Check that the timing marks on the camshaft timing exhaust gear assembly and camshaft timing gear assembly are as shown in the illustration.

      Tech Tips

      "A" is not a timing mark.

    4. Remove the crankshaft pulley set bolt.

  24. REMOVE TIMING CHAIN GUIDE


    1. B000N2D

      Remove the bolt and timing chain guide.

  25. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY


    1. B000KGNE01
      Text in Illustration
      *a Stopper Plate
      *b Plunger

      Allow the plunger to extend slightly, and then turn the stopper plate counterclockwise to release the lock. Once the lock is released, push the plunger into the No. 1 chain tensioner assembly.

    2. B000LFJE01
      Text in Illustration
      *a Pin

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

    3. B000KE3

      Remove the 2 bolts, No. 1 chain tensioner assembly and gasket.

  26. REMOVE CHAIN TENSIONER SLIPPER


    1. B000NI4

      Remove the bolt and chain tensioner slipper.

  27. REMOVE CHAIN SUB-ASSEMBLY


    1. Remove the chain sub-assembly.

  28. REMOVE NO. 1 CHAIN VIBRATION DAMPER


    1. B000MCS

      Remove the 2 bolts and No. 1 chain vibration damper.

  29. REMOVE CRANKSHAFT TIMING SPROCKET


    1. B000JE5

      Remove the crankshaft timing sprocket from the crankshaft.

  30. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY


    1. B000JUOE01
      Text in Illustration
      *a Hold
      B000K70 Turn

      Using a wrench to hold the hexagonal portion of the camshaft, remove the camshaft timing gear 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.

  31. REMOVE CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY


    1. B000LY2E01
      Text in Illustration
      *a Hold
      B000K70 Turn

      Using a wrench to hold the hexagonal portion of the No. 2 camshaft, 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.

  32. REMOVE OIL PIPE SUB-ASSEMBLY


    1. B000KRO

      Remove the bolt and oil pipe sub-assembly from the No. 4 camshaft bearing cap.

  33. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY


    1. B000JSPE01

      Uniformly loosen and remove the 20 bolts in the order shown in the illustration.

    2. B000M1H

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

      Note

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

      Tech Tips

      Tape the screwdriver tip before use.

  34. REMOVE CAMSHAFT BEARING CAP


    1. B000JYWE01

      Remove the 11 bolts in the order shown in the illustration.

    2. Remove the No. 1 camshaft bearing cap, No. 2 camshaft bearing cap, No. 3 camshaft bearing cap and No. 4 camshaft bearing cap.

      Tech Tips

      Arrange the removed parts in the correct order.

  35. REMOVE CAMSHAFT


    1. Remove the camshaft from the camshaft housing sub-assembly.

  36. REMOVE NO. 2 CAMSHAFT


    1. Remove the No. 2 camshaft from the camshaft housing sub-assembly.

  37. REMOVE OIL CONTROL VALVE FILTER


    1. B000JAM

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

  38. REMOVE NO. 1 CAMSHAFT BEARING


    1. B000K64

      Remove the No. 1 camshaft bearing from the No. 1 camshaft bearing cap.

  39. REMOVE NO. 2 CAMSHAFT BEARING


    1. B000NCB

      Remove the No. 2 camshaft bearing from the camshaft housing sub-assembly.

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


    1. Remove the 16 No. 1 valve rocker arm sub-assemblies.

      Tech Tips

      Arrange the removed parts in the correct order.

  41. REMOVE VALVE LASH ADJUSTER ASSEMBLY


    1. Remove the 16 valve lash adjuster assemblies from the cylinder head sub-assembly.

      Tech Tips

      Arrange the removed parts in the correct order.

  42. 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.

  43. REMOVE CAMSHAFT HOUSING STUD BOLT

    Note

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

  44. REMOVE CAMSHAFT BEARING CAP SETTING RING PIN

    Note

    It is not necessary to remove the camshaft bearing cap setting ring pin unless it is being replaced.

  45. REMOVE CAMSHAFT HOUSING STRAIGHT PIN

    Note

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

  46. REMOVE CYLINDER HEAD SUB-ASSEMBLY


    1. B000I2IE01

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

      Tech Tips

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

      Note


      • Be careful not to drop plate washers into the cylinder head sub-assembly.

      • Cylinder head warpage or cracking may result from removing bolts in the incorrect order.

    2. Remove the cylinder head sub-assembly.

  47. REMOVE CYLINDER HEAD GASKET


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

  48. REMOVE CYLINDER BLOCK WATER JACKET SPACER


    1. B000MGW

      Remove the cylinder block water jacket spacer from the cylinder block sub-assembly.

      Note

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

  49. REMOVE OIL FILTER CAP ASSEMBLY


    1. B000JOOE01
      Text in Illustration
      *a Pipe
      *b Hose

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

    2. B000N4H

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

    3. B000IFPE08
      Text in Illustration
      *1 Oil Filter Cap Assembly
      *2 O-ring
      *a Valve
      *b Hose

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

      Note

      Be sure to insert the pipe with the O-ring installed to the oil filter cap assembly.

      Tech Tips

      Place the hose end into a container before draining the engine oil from the hose.

    4. B000MV0

      Make sure that the engine oil is completely drained, and remove the pipe with hose and O-ring.

      Tech Tips

      Pull the pipe with hose as shown in the illustration to remove it.

    5. B000MF9E02
      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. B000LE8E07
      Text in Illustration
      *1 Oil Filter Element
      *2 Oil Filter Cap Assembly
      *3 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 in order to prevent the oil filter cap assembly from being damaged. Be sure to remove it by hand.

  50. REMOVE OIL PAN DRAIN PLUG


    1. Remove the oil pan drain plug and gasket from the oil pan sub-assembly.

  51. REMOVE OIL PAN SUB-ASSEMBLY


    1. B000N6JE01
      Text in Illustration
      *A Type A
      *B Type B
      B000K70 Bolt
      B000IB9 Nut

      Remove the 11 bolts and 2 nuts.

    2. B000HGN

      Insert the blade of an oil pan seal cutter between the oil pan sub-assembly and stiffening crankcase assembly, cut through the applied sealer and remove the oil pan sub-assembly.

      Note


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

      • Be careful not to damage the oil pan sub-assembly flange.

  52. REMOVE OIL STRAINER SUB-ASSEMBLY


    1. B000MN4

      Remove the 3 bolts, oil strainer sub-assembly and gasket.

  53. REMOVE ENGINE OIL LEVEL SENSOR


    1. Disconnect the engine oil level sensor connector.

    2. B000KG2

      Remove the clip from the engine oil level sensor.

    3. B000GZU

      Remove the 2 bolts.

    4. Disengage the clamp to remove the engine oil level sensor.

  54. REMOVE OIL LEVEL SENSOR BRACKET


    1. B000LW2

      Remove the 2 bolts and oil level sensor bracket from the stiffening crankcase assembly.

  55. REMOVE NO. 1 OIL PAN BAFFLE PLATE


    1. B000LFK

      Remove the clamp from the No. 1 oil pan baffle plate.

    2. Remove the 4 bolts and No. 1 oil pan baffle plate.

  56. INSPECT CRANKSHAFT BACKLASH


    1. B000NHC

      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.

  57. REMOVE ENGINE BALANCER ASSEMBLY


    1. B000M70

      Remove the 7 bolts and engine balancer assembly from the stiffening crankcase assembly.

      Note

      Do not disassemble the engine balancer assembly.

  58. INSPECT NO. 1 BALANCE SHAFT THRUST CLEARANCE


    1. B000NCM

      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.

  59. INSPECT NO. 2 BALANCE SHAFT THRUST CLEARANCE


    1. B000LXY

      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.

  60. REMOVE STIFFENING CRANKCASE ASSEMBLY


    1. B000NNB

      Remove the 7 bolts.

    2. B000KKUE01
      Text in Illustration
      *a LH Side
      *b RH Side

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

      Note

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

      Tech Tips

      Tape the screwdriver tip before use.

  61. REMOVE OIL FILTER BRACKET CLIP


    1. B000JE0

      Remove the oil filter bracket clip from the stiffening crankcase assembly.

  62. REMOVE STIFFENING CRANKCASE STUD BOLT

    Note

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

  63. REMOVE STIFFENING CRANKCASE RING PIN

    Note

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

  64. REMOVE REAR ENGINE OIL SEAL


    1. Remove the rear engine oil seal from the cylinder block sub-assembly.