ENGINE UNIT DISASSEMBLY

PROCEDURE


  1. REMOVE ENGINE COVER JOINT


    1. A01CXYF

      Remove the 3 engine cover joints.

  2. REMOVE SPARK PLUG

    Click here

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

    Click here

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

    Click here

  5. REMOVE CAMSHAFT POSITION SENSOR (for Intake Side)

    Click here

  6. REMOVE CAMSHAFT POSITION SENSOR (for Exhaust Side)

    Click here

  7. REMOVE OIL FILLER CAP SUB-ASSEMBLY


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

    2. Remove the gasket from the oil filler cap.

  8. REMOVE CRANKSHAFT POSITION SENSOR

    Click here

  9. REMOVE PCV VALVE

    Click here

  10. REMOVE PCV CASE


    1. A01CZ01

      Remove the 8 bolts and 2 nuts.

    2. A01CWXS

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

      Note

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

      Tech Tips

      Tape the screwdriver tip before use.

  11. REMOVE SEPARATOR CASE


    1. A01CWKX

      Remove the 2 bolts, separator case and gasket.

  12. REMOVE NO. 1 WATER BY-PASS PIPE


    1. A01CWED

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

  13. REMOVE WATER INLET

    Click here

  14. REMOVE THERMOSTAT

    Click here

  15. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY

    Click here

  16. REMOVE ENGINE WATER PUMP ASSEMBLY

    Click here

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

    Click here

  18. REMOVE WATER INLET HOUSING


    1. A01CYUU

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

  19. REMOVE CRANKSHAFT PULLEY


    1. A01CX23C01
      *a Turn
      *b Hold

      Using SST, hold the crankshaft pulley and loosen the pulley 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 holdingtool): 91551-80650 (quantity: 2)

    2. A01CYWRC07
      *1 Pulley Bolt

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

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

      Tech Tips

      Apply lubricant to the threads and end of SST.

  20. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY

    Click here

  21. REMOVE SPARK PLUG TUBE GASKET

    Click here

  22. REMOVE ENGINE MOUNTING BRACKET RH

    Click here

  23. REMOVE TIMING CHAIN COVER ASSEMBLY

    Click here

  24. REMOVE TIMING CHAIN COVER TIGHT PLUG


    1. A01CWEI

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

  25. REMOVE TIMING CHAIN COVER PLATE

    Click here

  26. REMOVE TIMING CHAIN COVER OIL SEAL

    Click here

  27. SET NO. 1 CYLINDER TO TDC/COMPRESSION

    Click here

  28. REMOVE TIMING CHAIN GUIDE

    Click here

  29. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY

    Click here

  30. REMOVE CHAIN TENSIONER SLIPPER

    Click here

  31. REMOVE CHAIN SUB-ASSEMBLY

  32. REMOVE NO. 1 CHAIN VIBRATION DAMPER

    Click here

  33. REMOVE CRANKSHAFT TIMING SPROCKET


    1. A01CY8Q

      Remove the crankshaft timing sprocket from the crankshaft.

  34. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY

    Click here

  35. REMOVE CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY

    Click here

  36. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY

    Click here

  37. REMOVE CAMSHAFT BEARING CAP

    Click here

  38. REMOVE OIL CONTROL VALVE FILTER


    1. A01CYRB

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

  39. REMOVE CAMSHAFT

    Click here

  40. REMOVE NO. 1 CAMSHAFT BEARING


    1. A01CX4C

      Remove the No. 1 camshaft bearing.

  41. REMOVE NO. 2 CAMSHAFT BEARING


    1. A01CX1Y

      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

    Click here

  46. REMOVE VALVE LASH ADJUSTER ASSEMBLY

    Click here

  47. REMOVE VALVE STEM CAP

    Click here

  48. REMOVE CYLINDER HEAD SUB-ASSEMBLY

    Click here

  49. REMOVE CYLINDER HEAD GASKET

    Click here

  50. REMOVE CYLINDER BLOCK WATER JACKET SPACER


    1. A01CWFD

      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 ELEMENT

    Click here

  52. REMOVE OIL PAN SUB-ASSEMBLY


    1. A01CWQT

      Remove the 11 bolts and 2 nuts.

    2. A01CW8Q

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

      Note


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

      • Be careful not to damage the stiffening crankcase flange.

  53. REMOVE OIL STRAINER SUB-ASSEMBLY


    1. A01CX2R

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

  54. REMOVE NO. 1 OIL PAN BAFFLE PLATE


    1. A01CXZP

      Remove the 5 bolts and No. 1 oil pan baffle plate.

  55. INSPECT CRANKSHAFT BACKLASH


    1. A01CYBI

      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. A01CXVX

      Remove the 7 bolts and engine balancer assembly.

      Note

      Do not disassemble the engine balancer assembly.

  57. INSPECT BALANCE SHAFT THRUST CLEARANCE

    Click here

  58. REMOVE STIFFENING CRANKCASE ASSEMBLY


    1. A01CY2O

      Remove the 7 bolts.

    2. A01CW0PC06
      *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.

      Note

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

      Tech Tips

      Tape the screwdriver tip before use.

  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. A01CWDZ

      Remove the rear engine oil seal from the cylinder block.