ENGINE UNIT DISASSEMBLY

PROCEDURE


  1. REMOVE ENGINE COVER JOINT


    1. A01COAC

      Remove the 3 engine cover joints.

  2. REMOVE SPARK PLUG

    Click here

  3. REMOVE KNOCK CONTROL SENSOR

    Click here

  4. REMOVE ENGINE COOLANT TEMPERATURE SENSOR

    Click here

  5. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY

    Click here

  6. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY

    Click here

  7. REMOVE CAMSHAFT POSITION SENSOR

    Click here

  8. REMOVE OIL FILLER CAP SUB-ASSEMBLY


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

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

  9. REMOVE CRANKSHAFT POSITION SENSOR

    Click here

  10. REMOVE PCV VALVE

    Click here

  11. REMOVE PCV CASE


    1. A01CN72

      Remove the 8 bolts and 2 nuts.

    2. A01CN4Z

      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.

  12. REMOVE SEPARATOR CASE


    1. A01CQA1

      Remove the 2 bolts, separator case and gasket.

  13. REMOVE CRANKSHAFT PULLEY ASSEMBLY


    1. A01CNWRC01
      *a Hold
      B002HVY Turn

      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 holding tool): 91551-80650 (quantity: 2)

    2. A01CNB1C01
      *1 Crankshaft Pulley Bolt
      *a Hold
      B002HVY Turn

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

      SST
      09950-50013   ( 09951-05010, 09952-05010, 09953-05020, 09954-05011, 09957-04010 )

      Tech Tips

      Apply lubricant to the threads and end of SST.

  14. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A01COJT

      Remove the 16 bolts, 3 seal washers, cylinder head cover sub-assembly and cylinder head cover gasket from the camshaft housing sub-assembly.

    2. A01O8I4

      Remove the 2 gaskets from the camshaft bearing caps.

  15. REMOVE SPARK PLUG TUBE GASKET


    1. A01CP8QC05
      *a Protective Tape

      Remove the 4 spark plug tube gaskets with a screwdriver.

      Note

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

      Tech Tips

      Tape the screwdriver tip before use.

  16. REMOVE ENGINE MOUNTING BRACKET RH

    A0002C2

    1. Remove the 4 bolts and engine mounting bracket RH.

  17. REMOVE ENGINE MOUNTING BRACKET RH STUD BOLT

    Note

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

  18. REMOVE TIMING CHAIN COVER ASSEMBLY

    Click here

  19. REMOVE TIMING CHAIN COVER OIL SEAL


    1. A01CRE4C13
      *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.

  20. REMOVE TIMING CHAIN COVER TIGHT PLUG


    1. A01CP7M

      Using a 14 mm hexagon wrench, remove the timing chain cover tight plug and gasket.

  21. REMOVE TIMING CHAIN COVER PLATE


    1. A01CQFF

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

  22. SET NO. 1 CYLINDER TO TDC/COMPRESSION


    1. Temporarily install the crankshaft pulley bolt.

      A01CQFQC13
      *1 Crankshaft Pulley Set Key - -
      *a Approximately 7° *b Approximately 32°
      *c Timing Mark - -

      Tech Tips

      "A" in the illustration is not a timing mark.

    2. Rotate the crankshaft clockwise so that the timing marks on the crankshaft timing sprocket, camshaft timing gear assembly and camshaft timing sprocket 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.

  23. REMOVE TIMING CHAIN GUIDE


    1. A01CP1D

      Remove the bolt and timing chain guide.

  24. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY


    1. A01CQ77C03
      *a Stopper Plate
      *b 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. A01CQZEC03
      *a Pin

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

    3. A01CO32

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

  25. REMOVE CHAIN TENSIONER SLIPPER


    1. A01CNSQ

      Remove the bolt and chain tensioner slipper.

  26. REMOVE CHAIN SUB-ASSEMBLY

  27. REMOVE NO. 1 CHAIN VIBRATION DAMPER


    1. A01CO4C

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

  28. REMOVE CRANKSHAFT TIMING SPROCKET


    1. A01CQ4S

      Remove the crankshaft timing sprocket from the crankshaft.

  29. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY


    1. A01CN6AC06
      *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 camshaft housing sub-assembly or spark plug tube with the wrench.

      • Do not disassemble the camshaft timing gear assembly.

  30. REMOVE CAMSHAFT TIMING SPROCKET


    1. A01COCFC02
      *a Hold
      *b Turn

      Hold the hexagonal portion of the No. 2 camshaft with a wrench and remove the bolt and camshaft timing sprocket.

      Note

      Be careful not to damage the camshaft housing sub-assembly or spark plug tube with the wrench.

  31. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY


    1. A01COY8N01

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

    2. A01CNC6

      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.

  32. REMOVE CAMSHAFT BEARING CAP


    1. A01CQT6N01

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

    2. Remove the 5 camshaft bearing caps.

      Tech Tips

      Arrange the removed parts in the correct order.

  33. REMOVE OIL CONTROL VALVE FILTER


    1. A01CNCZ

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

  34. REMOVE CAMSHAFT


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

  35. REMOVE NO. 2 CAMSHAFT


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

  36. REMOVE NO. 1 CAMSHAFT BEARING


    1. A01CPAY

      Remove the No. 1 camshaft bearing.

  37. REMOVE NO. 2 CAMSHAFT BEARING


    1. A01CNVV

      Remove the No. 2 camshaft bearing.

  38. REMOVE CAMSHAFT BEARING CAP SETTING RING PIN

    Note

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

  39. REMOVE CAMSHAFT HOUSING STUD BOLT

    Note

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

  40. REMOVE CAMSHAFT HOUSING STRAIGHT PIN

    Note

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

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


    1. Remove the 16 No. 1 valve rocker arm sub-assemblies from the cylinder head sub-assembly.

      Tech Tips

      Arrange the removed parts in the correct order.

  42. 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.

  43. 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.

  44. REMOVE CYLINDER HEAD SUB-ASSEMBLY

    Click here

  45. REMOVE CYLINDER HEAD GASKET

    Click here

  46. REMOVE CYLINDER BLOCK WATER JACKET SPACER


    1. A01COG1

      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.

  47. REMOVE OIL FILTER ELEMENT

    Click here

  48. REMOVE OIL PAN SUB-ASSEMBLY


    1. A0000IZ

      Remove the 11 bolts and 2 nuts.

    2. A01CPJ3

      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.

  49. REMOVE OIL STRAINER SUB-ASSEMBLY


    1. A01CPQ9

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

  50. REMOVE NO. 1 OIL PAN BAFFLE PLATE


    1. A0001FH

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

  51. INSPECT CRANKSHAFT BACKLASH


    1. A01CQRN

      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.

  52. REMOVE ENGINE BALANCER ASSEMBLY


    1. A01CRQN

      Remove the 7 bolts and engine balancer assembly.

      Note

      Do not disassemble the engine balancer assembly.

  53. INSPECT BALANCE SHAFT THRUST CLEARANCE

    Click here

  54. REMOVE STIFFENING CRANKCASE ASSEMBLY


    1. A01COUV

      Remove the 7 bolts.

    2. A01CNQHC06
      *a LH Side
      *b RH Side

      Using a screwdriver, remove the stiffening crankcase assembly by prying between the stiffening crankcase assembly 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 assembly.

      Tech Tips

      Tape the screwdriver tip before use.

  55. REMOVE CYLINDER BLOCK STUD BOLT

    Note

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

  56. REMOVE STIFFENING CRANKCASE STUD BOLT

    Note

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

  57. REMOVE STIFFENING CRANKCASE RING PIN

    Note

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

  58. REMOVE REAR ENGINE OIL SEAL


    1. A01CPRN

      Remove the rear engine oil seal from the cylinder block.