ENGINE UNIT DISASSEMBLY

PROCEDURE


  1. REMOVE ENGINE COVER JOINT


    1. A0006ML

      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.

  9. REMOVE OIL FILLER CAP GASKET


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

  10. REMOVE CRANKSHAFT POSITION SENSOR

    Click here

  11. REMOVE VENTILATION VALVE SUB-ASSEMBLY

    Click here

  12. REMOVE VENTILATION CASE SUB-ASSEMBLY


    1. A00040R

      Remove the 8 bolts and 2 nuts.

    2. A0008YP

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

      Note

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

      Tech Tips

      Tape the screwdriver tip before use.

  13. REMOVE SEPARATOR CASE


    1. A000855

      Remove the 2 bolts, separator case and gasket.

  14. REMOVE CRANKSHAFT PULLEY


    1. A0008AWE01
      Text in Illustration
      *a Hold
      *b Turn

      Using SST, hold the crankshaft pulley and loosen the pulley bolt. Further loosen the pulley 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. A0005K6E10
      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.

  15. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A00071T

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

    2. A00093X

      Remove the 2 camshaft bearing cap oil hole gaskets.

  16. REMOVE STUD BOLT

    Note

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


    1. A00064D

      Using an E6 "TORX" socket wrench, remove the 3 stud bolts from the cylinder head cover sub-assembly.

  17. REMOVE SPARK PLUG TUBE GASKET


    1. A0005Z9E03
      Text in Illustration
      *1 Tape

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

      Note

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

      Tech Tips

      Tape the screwdriver tip before use.

  18. REMOVE ENGINE MOUNTING BRACKET RH

    Click here

  19. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY

    Click here

  20. REMOVE OIL PUMP RELIEF VALVE PLUG


    1. A0005FN

      Using a 14 mm hexagon wrench, remove the oil pump relief valve plug and gasket.

  21. REMOVE TIMING CHAIN COVER PLATE


    1. A0005K7

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

  22. REMOVE TIMING CHAIN COVER OIL SEAL

    Click here

  23. SET NO. 1 CYLINDER TO TDC/COMPRESSION

    Click here

  24. REMOVE TIMING CHAIN GUIDE

    Click here

  25. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY

    Click here

  26. REMOVE CHAIN TENSIONER SLIPPER

    Click here

  27. REMOVE CHAIN SUB-ASSEMBLY


    1. Remove the chain sub-assembly.

  28. REMOVE NO. 1 CHAIN VIBRATION DAMPER

    Click here

  29. REMOVE CRANKSHAFT TIMING SPROCKET


    1. A0004LX

      Remove the crankshaft timing sprocket from the crankshaft.

  30. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY

    Click here

  31. REMOVE CAMSHAFT TIMING SPROCKET

    Click here

  32. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY

    Click here

  33. REMOVE CAMSHAFT BEARING CAP

    Click here

  34. REMOVE OIL CONTROL VALVE FILTER


    1. A0007OI

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

  35. REMOVE CAMSHAFT

    Click here

  36. REMOVE NO. 1 CAMSHAFT BEARING


    1. A00057P

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

  37. REMOVE NO. 2 CAMSHAFT BEARING


    1. A0006JR

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

  38. REMOVE STUD BOLT

    Note

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


    1. A0008WG

      Using an E8 "TORX" socket wrench, remove the stud bolt from the camshaft housing sub-assembly.

  39. REMOVE CAMSHAFT BEARING CAP SETTING RING PIN

    Note

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


    1. A00057L

      Remove the 10 camshaft bearing cap setting ring pins from the camshaft housing sub-assembly.

  40. REMOVE STRAIGHT PIN

    Note

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


    1. A0004CN

      Remove the 2 straight pins from the camshaft housing sub-assembly.

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

    Click here

  42. REMOVE VALVE LASH ADJUSTER ASSEMBLY

    Click here

  43. REMOVE VALVE STEM CAP

    Click here

  44. REMOVE CYLINDER HEAD SUB-ASSEMBLY

    Click here

  45. REMOVE CYLINDER HEAD GASKET

    Click here

  46. REMOVE CYLINDER BLOCK WATER JACKET SPACER


    1. A0004Y8

      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.

  47. REMOVE OIL FILTER CAP ASSEMBLY

    Click here

  48. REMOVE OIL PAN DRAIN PLUG


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

  49. REMOVE OIL PAN SUB-ASSEMBLY


    1. A00041RE09
      Text in Illustration
      *1 Nut

      Remove the 11 bolts and 2 nuts.

    2. A0004SY

      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 stiffening crankcase assembly contact surface of the oil pan sub-assembly.

      • Be careful not to damage the stiffening crankcase flange.

  50. REMOVE OIL STRAINER SUB-ASSEMBLY


    1. A0005XV

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

  51. REMOVE NO. 1 OIL PAN BAFFLE PLATE


    1. A00065Q

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

  52. INSPECT CRANKSHAFT BACKLASH


    1. A0009E1

      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.

  53. REMOVE ENGINE BALANCER ASSEMBLY


    1. A0004TI

      Remove the 7 bolts and engine balancer assembly.

      Note

      Do not disassemble the engine balancer assembly.

  54. INSPECT NO. 1 BALANCE SHAFT THRUST CLEARANCE

    Click here

  55. INSPECT NO. 2 BALANCE SHAFT THRUST CLEARANCE

    Click here

  56. REMOVE STIFFENING CRANKCASE ASSEMBLY


    1. A00059S

      Remove the 7 bolts.

    2. A00080VE03
      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.

  57. REMOVE STUD BOLT

    Note

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


    1. A0005AW

      Using an E5 and E8 "TORX" socket wrench, remove the 3 stud bolts from the stiffening crankcase assembly.

  58. REMOVE RING PIN

    Note

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


    1. A0009OK

      Remove the 2 ring pins from the stiffening crankcase assembly.

  59. REMOVE REAR ENGINE OIL SEAL


    1. A0004VU

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