ENGINE UNIT DISASSEMBLY


  1. REMOVE ENGINE COVER JOINT


    1. A01G5JQ

      Remove the 3 engine cover joints.

  2. REMOVE SPARK PLUG


    1. A01G7LS

      Remove the 4 spark plugs.

  3. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY


    1. Camshaft timing oil control valve assembly (for exhaust side)


      1. A01G44T

        Disconnect the camshaft timing oil control valve assembly connector.

      2. Remove the bolt and camshaft timing oil control valve assembly.

      3. A01G4UFE06
        Text in Illustration
        *1 O-ring

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

    2. Camshaft timing oil control valve assembly (for intake side)


      1. A01G8XL

        Disconnect the camshaft timing oil control valve assembly connector.

      2. Remove the bolt and camshaft timing oil control valve assembly.

      3. A01G4UFE06
        Text in Illustration
        *1 O-ring

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

  4. REMOVE CAMSHAFT POSITION SENSOR


    1. Camshaft position sensor (for Exhaust Side)


      1. A01G83I

        Disconnect the camshaft position sensor connector.

      2. Remove the bolt and camshaft position sensor.

    2. Camshaft position sensor (for Intake Side)


      1. A01G6UK

        Disconnect the camshaft position sensor connector.

      2. Remove the bolt and camshaft position sensor.

  5. 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.

  6. REMOVE CRANKSHAFT POSITION SENSOR


    1. A01G74R

      Disconnect the crankshaft position sensor connector.

    2. Remove the bolt and crankshaft position sensor.

  7. REMOVE VENTILATION VALVE SUB-ASSEMBLY


    1. A01G9O1

      Disconnect the No. 2 ventilation hose from the ventilation valve sub-assembly.

    2. A01G6PEE02
      Text in Illustration
      *1 19 mm Deep Socket Wrench

      Using a 19 mm deep socket wrench, remove the ventilation valve sub-assembly from the ventilation case sub-assembly.

  8. REMOVE VENTILATION CASE SUB-ASSEMBLY


    1. A01G4DZ

      Remove the 8 bolts and 2 nuts.

    2. A01G6GQ

      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.

  9. REMOVE SEPARATOR CASE


    1. A01G7WX

      Remove the 2 bolts, separator case and gasket.

  10. REMOVE NO. 1 WATER BY-PASS PIPE


    1. A01G7OR

      Remove the bolt, 2 nuts, No. 1 water by-pass pipe and gasket.

  11. REMOVE WATER INLET


    1. A01G5GF

      Remove the 2 nuts and water inlet.

  12. REMOVE THERMOSTAT


    1. Remove the thermostat.

    2. Remove the gasket from the thermostat.

  13. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY


    1. A01G6NB

      Remove the bolt and V-ribbed belt tensioner assembly.

  14. REMOVE ENGINE WATER PUMP ASSEMBLY


    1. A01G9Q8

      Remove the 7 bolts, engine water pump assembly and gasket.

  15. REMOVE WATER INLET HOUSING


    1. A01G5X3

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

  16. REMOVE CRANKSHAFT PULLEY


    1. A01G473E12
      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

      SST (Crankshaft pulley holding tool) Fixing bolt part No. : 91551-80650(2 pcs)

    2. A01G6OPE04
      Text in Illustration
      *1 Pulley Bolt
      *a Hold
      *b Turn

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

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

      Tech Tips

      Apply a lubricant to the threads and end of SST.

  17. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A01G8SM

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

    2. A01G8SQ

      Remove the 3 camshaft bearing cap oil hole gaskets.

  18. REMOVE SPARK PLUG TUBE GASKET


    1. A01G7HA

      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.

  19. REMOVE ENGINE MOUNTING BRACKET RH


    1. A01G81R

      Remove the 5 bolts and engine mounting bracket RH.

  20. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY


    1. A01G8OY

      Remove the 17 bolts and 2 nuts.

    2. A01G4E4

      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.

      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. A01G6FE

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

  21. REMOVE TIMING CHAIN COVER TIGHT PLUG


    1. A01G6VF

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

  22. REMOVE TIMING CHAIN COVER PLATE


    1. A01G57G

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

  23. REMOVE TIMING CHAIN COVER OIL SEAL


    1. A01G8LVE04
      Text in Illustration
      *1 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.

  24. SET NO. 1 CYLINDER TO TDC/COMPRESSION


    1. Temporarily install the crankshaft pulley bolt.

      A01G4FEE03
      Text in Illustration
      *a Approximately 7° *b Approximately 32°
      *c Timing Mark *d Crankshaft Pulley Key

      Tech Tips

      "A" 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 exhaust gear assembly are as shown in the illustration.

      Tech Tips

      If the timing marks do not align, turn the crankshaft 1 revolution (360°) to align the timing marks as shown in the illustration.

    3. Remove the crankshaft pulley bolt.

  25. REMOVE TIMING CHAIN GUIDE


    1. A01G6XS

      Remove the bolt and timing chain guide.

  26. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY


    1. A01G553E02
      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 No. 1 chain tensioner assembly.

    2. A01G7HWE02
      Text in Illustration
      *1 Pin

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

    3. A01G5UC

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

  27. REMOVE CHAIN TENSIONER SLIPPER


    1. A01G5YD

      Remove the bolt and chain tensioner slipper.

  28. REMOVE CHAIN SUB-ASSEMBLY


    1. Remove the chain sub-assembly.

  29. REMOVE NO. 1 CHAIN VIBRATION DAMPER


    1. A01G9DH

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

  30. REMOVE CRANKSHAFT TIMING SPROCKET


    1. A01G8CS

      Remove the crankshaft timing sprocket from the crankshaft.

  31. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY


    1. A01G59VE01
      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.

  32. REMOVE CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY


    1. A01G8RQE01
      Text in Illustration
      *a Hold
      *b Turn

      Hold the hexagonal portion of the No. 2 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.

  33. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY


    1. A01G84FE01

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

    2. A01G7KK

      Remove the camshaft housing sub-assembly 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 sub-assembly and camshaft housing sub-assembly.

  34. REMOVE CAMSHAFT BEARING CAP


    1. A01G59JE01

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

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

      Tech Tips

      Arrange the removed parts in the correct order.

  35. REMOVE OIL CONTROL VALVE FILTER


    1. A01G5I2

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

  36. REMOVE CAMSHAFT


    1. Remove the camshaft and No. 2 camshaft.

  37. REMOVE NO. 1 CAMSHAFT BEARING


    1. A01G9CC

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

  38. REMOVE NO. 2 CAMSHAFT BEARING


    1. A01G5ZL

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

  39. REMOVE CAMSHAFT HOUSING STUD BOLT

    Note

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

  40. 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.

  41. REMOVE CAMSHAFT HOUSING STRAIGHT PIN

    Note

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

  42. 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.

  43. 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.

  44. 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.

  45. REMOVE CYLINDER HEAD SUB-ASSEMBLY


    1. A01G9SEE01

      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 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.

      • Head warpage or cracking could result from removing bolts in the incorrect order.

    2. Remove the cylinder head sub-assembly.

  46. REMOVE CYLINDER HEAD GASKET


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

  47. REMOVE CYLINDER BLOCK WATER JACKET SPACER


    1. A01G4CN

      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.

  48. REMOVE OIL FILTER CAP ASSEMBLY


    1. A01G7X6E06
      Text in Illustration
      *1 Pipe
      *2 Hose

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

    2. A01G9TJ

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

    3. A01G798E04
      Text in Illustration
      *1 Valve
      *2 Oil Filter Cap Assembly
      *3 O-ring
      *4 Pipe

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

      Note

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

      Tech Tips

      Use a container to catch the draining oil.

    4. A01G70F

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

    5. A01G7ADE02
      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. A01G5ZCE07
      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

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

  49. REMOVE OIL PAN DRAIN PLUG


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

  50. REMOVE OIL PAN SUB-ASSEMBLY


    1. A01G6V5E03
      Text in Illustration
      *1 Nut

      Remove the 11 bolts and 2 nuts.

    2. A01G8W9

      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.

  51. REMOVE OIL STRAINER SUB-ASSEMBLY


    1. A01G7J7

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

  52. REMOVE NO. 1 OIL PAN BAFFLE PLATE


    1. A01G5PG

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

  53. INSPECT CRANKSHAFT BACKLASH


    1. A01G7WY

      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.

  54. REMOVE ENGINE BALANCER ASSEMBLY


    1. A01G9M7

      Remove the 7 bolts and engine balancer assembly.

      Note

      Do not disassemble the engine balancer assembly.

  55. INSPECT BALANCE SHAFT THRUST CLEARANCE


    1. A01G56O

      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.

  56. REMOVE STIFFENING CRANKCASE ASSEMBLY


    1. A01G8RH

      Remove the 7 bolts.

    2. A01G6H2E03
      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 STIFFENING CRANKCASE STUD BOLT

    Note

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

  58. REMOVE STIFFENING CRANKCASE RING PIN

    Note

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

  59. REMOVE REAR ENGINE OIL SEAL


    1. A01G5XC

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