ENGINE UNIT DISASSEMBLY

REMOVE SPARK PLUG

1. 

   Remove the 4 spark plugs.

REMOVE OIL FILTER SUB-ASSEMBLY

1. Using SST, remove the oil filter sub-assembly.

   09228-06501

SET NO. 1 CYLINDER TO TDC/COMPRESSION

1. 

   Turn the crankshaft pulley until the groove and the timing mark "0" on the timing chain cover are aligned.

   Table 3. Text in Illustration

   *1	Timing Mark
   *2	Paint Mark
   *3	Groove

2. Check that each timing mark on the camshaft timing gear and sprocket is aligned with each timing mark located on the No. 1 and No. 2 bearing caps as shown in the illustration.

   If not, turn the crankshaft pulley 1 revolution (360°) to align the timing marks as illustrated.

3. Place paint marks on the chain in alignment with the timing marks on the camshaft timing gear and camshaft timing sprocket.

REMOVE CRANKSHAFT PULLEY

1. 

   Using SST, hold the crankshaft pulley in place and loosen the pulley bolt.

   09213-54015	91651-60855
   09330-00021

2. 

   Using SST, remove the crankshaft pulley.

   09950-50013	09951-05010	09952-05010	09953-05020	09954-05021
   09950-40011	09957-04010

   Tip:

   If necessary, remove the pulley and pulley bolt using SST.

REMOVE WATER PUMP PULLEY

1. 

   Using SST, remove the 4 bolts and water pump pulley.

   09960-10010

   09962-01000

   09963-00700

REMOVE WATER PUMP ASSEMBLY (for TMC Made Engine)

1. 

   Remove the clamp of the crankshaft position sensor from the water pump.

2. Disconnect the wire of the crankshaft position sensor from the clamp bracket.

3. 

   Remove the 4 bolts, 2 nuts and clamp bracket.

   Table 4. Text in Illustration

   *1	Clamp Bracket

4. 

   Using a screwdriver, pry between the water pump and cylinder block, and then remove the water pump.

   Tip:

   Tape the screwdriver tip before use.

   Note:

   Be careful not to damage the contact surfaces of the water pump and cylinder block.

REMOVE WATER PUMP ASSEMBLY (except TMC Made Engine)

1. 

   Disconnect the connector of the crankshaft position sensor.

   Table 5. Text in Illustration

   *1	Clamp Bracket

2. Disconnect the wire of the crankshaft position sensor from the clamp brackets.

3. 

   Remove the 4 bolts, 2 nuts and 2 clamp brackets.

   Table 6. Text in Illustration

   *1	Clamp Bracket

4. 

   Using a screwdriver, pry between the water pump and cylinder block, and then remove the water pump.

   Tip:

   Tape the screwdriver tip before use.

   Note:

   Be careful not to damage the contact surfaces of the water pump and cylinder block.

REMOVE TIMING CHAIN COVER SUB-ASSEMBLY

1. 

   Remove the 3 bolts and engine mounting bracket RH.

2. 

   Using an E10 "TORX" socket, remove the stud bolt for the V-ribbed belt tensioner.

3. 

   Remove the 12 bolts and 2 nuts.

4. 

   Remove the timing chain cover by prying the portions between the timing chain cover, cylinder head and cylinder block with a screwdriver.

   Table 7. Text in Illustration

   *1	Protective Tape

   Note:

   Be careful not to damage the contact surfaces of the timing chain cover, cylinder head or cylinder block.

   Tip:

   Tape the screwdriver tip before use.

REMOVE FRONT CRANKSHAFT OIL SEAL

1. 

   Place the timing chain cover on wooden blocks.

   Table 8. Text in Illustration

   *1	Protective Tape

2. Using a screwdriver, pry out the oil seal.

   Note:

   Do not damage the surface of the oil seal press fit hole.

   Tip:

   Tape the screwdriver tip before use.

REMOVE NO. 1 CRANKSHAFT POSITION SENSOR PLATE

1. 

   Remove the No. 1 crankshaft position sensor plate.

REMOVE TIMING CHAIN GUIDE

1. 

   Remove the bolt and timing chain guide.

REMOVE CHAIN TENSIONER SLIPPER

1. 

   Remove the bolt and chain tensioner slipper.

REMOVE NO. 1 CHAIN VIBRATION DAMPER

1. 

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

REMOVE CHAIN SUB-ASSEMBLY

1. Remove the chain sub-assembly.

REMOVE CRANKSHAFT TIMING SPROCKET

1. 

   Remove the crankshaft timing gear or sprocket from the crankshaft.

REMOVE NO. 2 CHAIN SUB-ASSEMBLY

1. 

   Turn the crankshaft 90° counterclockwise to align the adjusting hole on the oil pump drive shaft sprocket with the groove on the oil pump.

   Table 9. Text in Illustration

   *1

   Groove

2. 

   Insert a 4 mm diameter bar into the adjusting hole of the oil pump drive shaft sprocket to lock the gear in position, and then remove the nut.

   Table 10. Text in Illustration

   *1

   Groove

3. 

   Remove the bolt, chain tensioner plate and spring.

   Table 11. Text in Illustration

   *1	Bolt
   *2	Chain Tensioner Plate
   *3	Spring

4. Remove the oil pump drive sprocket, oil pump drive shaft sprocket and No. 2 chain.

REMOVE CAMSHAFT TIMING GEAR ASSEMBLY

1. 

   Clamp the camshaft in a vise, and make sure that the camshaft timing gear assembly does not rotate.

   Table 12. Text in Illustration

   *1	Vinyl Tape
   *2	Rubber
   *a	Advance Side Path
   *b	Close
   *c	Open

2. Cover all the oil path with vinyl tape except the advance side path shown in the illustration.

3. 

   Apply air pressure of 150 kPa (1.5 kgf/cm², 22 psi) to the oil path, then turn the camshaft timing gear assembly to the advance direction (counterclockwise) by hand.

   CAUTION:

   Cover the paths with a piece of cloth to avoid oil splashes.

   Tip:

   Depending on the air pressure, the camshaft timing gear assembly may turn to the advance side without applying force by hand. Also, if the pressure is difficult to apply because of air leakage from a path, the lock pin may be difficult to release.

4. 

   Remove the flange bolt and camshaft timing gear.

   Note:
   

   • Be sure not to remove the other 4 bolts.

   • When reusing the camshaft timing gear, release the straight pin lock first, then install the gear.

REMOVE CYLINDER HEAD SUB-ASSEMBLY

1. 

   In several steps, uniformly loosen and remove the 10 cylinder head bolts and 10 plate washers with a 10 mm bi-hexagon wrench in the sequence shown in the illustration.

   Note:

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

2. 

   Using a screwdriver with its tip wrapped with tape, pry between the cylinder head and cylinder block, and remove the cylinder head.

   Note:

   Be careful not to damage the contact surfaces between the cylinder head and cylinder block.

REMOVE OIL PUMP ASSEMBLY

1. 

   Remove the 3 bolts, oil pump and gasket.

INSPECT BALANCESHAFT THRUST CLEARANCE

1. Install the balanceshafts (Click here).

2. 

   Using a dial indicator, measure the thrust clearance while moving the balanceshaft 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 greater than the maximum, replace the balanceshaft housing and bearings. If necessary, replace the balanceshaft.

INSPECT BALANCESHAFT OIL CLEARANCE

1. Clean each bearing and journal.

2. Check each bearing and journal for pitting and scratches.

   If a bearing or journal is damaged, replace the bearings. If necessary, replace the balanceshaft.

3. Place the No. 1 and No. 2 balanceshafts onto the crankcase.

4. 

   Lay a strip of Plastigage across each journal.

   Table 17. Text in Illustration

   *1	Plastigage

5. Install the balanceshaft housing (Click here).

   Note:

   Do not turn the balanceshafts.

6. Remove the balanceshafts (Click here).

7. 

   Measure the Plastigage at its widest point.

   Standard oil clearance
   0.022 to 0.049 mm (0.000866 to 0.00193 in.)

   Maximum oil clearance
   0.049 mm (0.00193 in.)

   Note:

   Remove the Plastigage completely after the measurement.

   If the oil clearance is greater than the maximum, replace the bearing. If necessary, replace the balanceshaft.

   Table 18. Text in Illustration

   *1	Plastigage

8. 

   If replacing a bearing, select a new one with the same number.

   Table 19. Text in Illustration

   *a	Number Mark
   *b	Front No. 1 Journal Bore
   *c	Rear No. 1 Journal Bore
   *d	Front No. 2 Journal Bore
   *e	Rear No. 2 Journal Bore

   Standard Balanceshaft Housing Journal Bore Diameter
   Item Specified Condition Mark 1 26.000 to 26.006 mm (1.0236 to 1.0239 in.) Mark 2 26.007 to 26.012 mm (1.0239 to 1.0241 in.) Mark 3 26.013 to 26.018 mm (1.0241 to 1.0243 in.)

   Standard Bearing Center Wall Thickness
   Item Specified Condition Mark 1 1.486 to 1.489 mm (0.05850 to 0.05862 in.) Mark 2 1.490 to 1.492 mm (0.05866 to 0.05874 in.) Mark 3 1.493 to 1.495 mm (0.0588 to 0.0589 in.)

   Standard balanceshaft journal diameter
   22.985 to 23.000 mm (0.9049 to 0.9055 in.)

9. Inspect the balanceshaft housing bolts.

   
   
   1. 

      Using a vernier caliper, measure the length of the bolts from the seat to the end.

      Standard bolt length
      58.3 to 59.7 mm (2.295 to 2.350 in.)

      Maximum bolt length
      60.3 mm (2.374 in.)

      If the bolt length is greater than the maximum, replace the balanceshaft housing bolt.

      Table 20. Text in Illustration

      *a	Measurement Length

REMOVE REAR CRANKSHAFT OIL SEAL

1. 

   Using a knife, cut off the lip of the oil seal.

   Table 21. Text in Illustration

   *1	Protective Tape
   *a	Cut Position

2. Using a screwdriver, pry out the oil seal.

   Note:

   After removing, check the crankshaft for damage. If damaged, smooth the surface with 400-grit sandpaper.

   Tip:

   Tape the screwdriver tip before use.