ENGINE UNIT DISASSEMBLY


  1. REMOVE ENGINE COVER JOINT


    1. A01ET2O

      Remove the 3 joints.

  2. REMOVE SPARK PLUG


    1. A01EU8Z

      Using a spark plug wrench, remove the 4 spark plugs.

  3. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY


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


      1. A01EW7I

        Disconnect the oil control valve connector.

      2. Remove the bolt and oil control valve.

      3. A01EWYWE06
        Text in Illustration
        *1 O-ring

        Remove the O-ring from the oil control valve.

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


      1. A01EYRR

        Disconnect the oil control valve connector.

      2. Remove the bolt and oil control valve.

      3. A01EWYWE06
        Text in Illustration
        *1 O-ring

        Remove the O-ring from the oil control valve.

  4. REMOVE CAMSHAFT POSITION SENSOR


    1. Camshaft position sensor (for Exhaust Side)


      1. A01EWLU

        Disconnect the sensor connector.

      2. Remove the bolt and sensor.

    2. Camshaft position sensor (for Intake Side)


      1. A01EUYX

        Disconnect the sensor connector.

      2. Remove the bolt and sensor.

  5. REMOVE OIL FILLER CAP SUB-ASSEMBLY


    1. Remove the oil filler cap from the cylinder head.

    2. Remove the gasket from the oil filler cap.

  6. REMOVE CRANKSHAFT POSITION SENSOR

    A01EZ0W

    1. Disconnect the sensor connector.

    2. Remove the bolt and sensor.

  7. REMOVE VENTILATION VALVE SUB-ASSEMBLY


    1. A01EW4B

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

    2. A01EVOLE02
      Text in Illustration
      *1 19 mm Deep Socket Wrench

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

  8. REMOVE VENTILATION CASE SUB-ASSEMBLY


    1. A01EW00

      Remove the 8 bolts and 2 nuts.

    2. A01EXEM

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

      Tech Tips

      Tape the screwdriver tip before use.

      Note

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

  9. REMOVE SEPARATOR CASE


    1. A01EU29

      Remove the 2 bolts, separator case and gasket.

  10. REMOVE NO. 1 WATER BY-PASS PIPE


    1. A01EU05

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

  11. REMOVE WATER INLET


    1. A01EV00

      Remove the 2 nuts and water inlet.

  12. REMOVE V-RIBBED BELT


    1. A01EV16

      Attach a wrench to the hexagonal portion of the belt tensioner as shown in the illustration, rotate the belt tensioner clockwise, and remove the V-ribbed belt.

  13. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY


    1. A01EWOV

      Remove the bolt and V-ribbed belt tensioner.

  14. REMOVE ENGINE WATER PUMP ASSEMBLY


    1. A01EXSY

      Remove the 7 bolts, engine water pump and gasket.

  15. REMOVE WATER INLET HOUSING


    1. A01EY4A

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

  16. REMOVE CRANKSHAFT PULLEY


    1. A01EUANE14
      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. A01EWKGE04
      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.

  17. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A01EURE

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

    2. A01EV5L

      Remove the 3 gaskets from the camshaft bearing caps.

  18. REMOVE SPARK PLUG TUBE GASKET


    1. A01EYBM

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

      Note

      Be careful not to damage the cylinder head cover.

      Tech Tips

      Tape the screwdriver tip before use.

  19. REMOVE ENGINE MOUNTING BRACKET RH


    1. A01EWHF

      Remove the 3 bolts and engine mounting bracket RH.

  20. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY


    1. A01ET7M

      Remove the 17 bolts and 2 nuts.

    2. A01EX2V

      Remove the timing chain cover by prying between the timing chain cover and cylinder head, camshaft housing, cylinder block and stiffening crankcase with a screwdriver as shown in the illustration.

      Note

      Be careful not to damage the contact surfaces of the cylinder head, camshaft housing, cylinder block, stiffening crankcase or chain cover.

      Tech Tips

      Tape the screwdriver tip before use.

    3. A01ETJC

      Remove the 3 gaskets from the stiffening crankcase.

  21. REMOVE TIMING CHAIN COVER TIGHT PLUG


    1. A01EWN1

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

  22. REMOVE TIMING CHAIN COVER PLATE


    1. A01EX56

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

  23. REMOVE TIMING CHAIN COVER OIL SEAL


    1. A01EX4DE04
      Text in Illustration
      *1 Wooden Block

      Using a screwdriver and wooden block, pry out the oil seal.

      Note

      Do not damage the surface of the 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.

      A01ETOLE03
      Text in Illustration
      *a Approximately 7° *b Approximately 32°
      *c Timing Mark *d Key

      Tech Tips

      "A" is not a timing mark.

    2. Rotate the crankshaft clockwise so that the timing marks on the crankshaft timing gear and camshaft timing gears 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.

  25. REMOVE TIMING CHAIN GUIDE


    1. A01EV0O

      Remove the bolt and timing chain guide.

  26. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY


    1. A01EY8YE02
      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 tensioner.

    2. A01ET20E02
      Text in Illustration
      *1 Pin

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

    3. A01EXZH

      Remove the 2 bolts, chain tensioner and gasket.

  27. REMOVE CHAIN TENSIONER SLIPPER


    1. A01EYU8

      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. A01EUB3

      Remove the 2 bolts and chain vibration damper.

  30. REMOVE CRANKSHAFT TIMING SPROCKET


    1. A01EUIM

      Remove the crankshaft timing sprocket from the crankshaft.

  31. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY


    1. A01EW5L

      Hold the hexagonal portion of the camshaft with a wrench and remove the bolt and camshaft timing gear.

      Note


      • Be careful not to damage the cylinder head or spark plug tube with the wrench.

      • Do not disassemble the camshaft timing gear.

  32. REMOVE CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY


    1. A01EVJN

      Hold the hexagonal portion of the camshaft with a wrench and remove the bolt and camshaft timing exhaust gear.

      Note


      • Be careful not to damage the cylinder head or spark plug tube with the wrench.

      • Do not disassemble the camshaft timing exhaust gear.

  33. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY


    1. A01EYLQE01

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

    2. A01EYZF

      Remove the camshaft housing by prying between the cylinder head and camshaft housing with a screwdriver.

      Tech Tips

      Tape the screwdriver tip before use.

      Note

      Be careful not to damage the contact surfaces of the cylinder head and camshaft housing.

  34. REMOVE CAMSHAFT BEARING CAP


    1. A01EXYCE01

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

    2. Remove the 5 bearing caps.

      Tech Tips

      Arrange the removed parts in the correct order.

  35. REMOVE OIL CONTROL VALVE FILTER


    1. A01EWXX

      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. A01ETPB

      Remove the No. 1 camshaft bearing.

  38. REMOVE NO. 2 CAMSHAFT BEARING


    1. A01EXWJ

      Remove the No. 2 camshaft bearing.

  39. REMOVE CAMSHAFT HOUSING STUD BOLT

    Note

    If a 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 ring pin unless it is being replaced.

  41. REMOVE CAMSHAFT HOUSING STRAIGHT PIN

    Note

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

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


    1. Remove the 16 valve rocker arms from the cylinder head.

      Tech Tips

      Arrange the removed parts in the correct order.

  43. REMOVE VALVE LASH ADJUSTER ASSEMBLY


    1. Remove the 16 valve lash adjusters from the cylinder head.

      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.

      Tech Tips

      Arrange the removed parts in the correct order.

  45. REMOVE CYLINDER HEAD SUB-ASSEMBLY


    1. A01EU6JE01

      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 plate washers.

      Tech Tips

      Be sure to keep the removed parts separate for each installation position.

      Note


      • Be careful not to drop washers into the cylinder head.

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

    2. Remove the cylinder head.

  46. REMOVE CYLINDER HEAD GASKET


    1. Remove the cylinder head gasket from the cylinder block.

  47. REMOVE CYLINDER BLOCK WATER JACKET SPACER


    1. A01EVFA

      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.

  48. REMOVE OIL FILTER CAP ASSEMBLY


    1. A01EZ3AE06
      Text in Illustration
      *1 Pipe
      *2 Hose

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

    2. A01ET0Z

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

    3. A01EYABE04
      Text in Illustration
      *1 Valve
      *2 Cap
      *3 O-ring
      *4 Pipe

      Install the pipe to the oil filter cap.

      Note

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

      Tech Tips

      Use a container to catch the draining oil.

    4. A01EX15

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

    5. A01EVFME02
      Text in Illustration
      *1 Oil Filter Bracket Clip

      Using SST, remove the oil filter cap.

      SST
      09228-06501

      Note

      Do not remove the oil filter bracket clip.

    6. A01EUPGE07
      Text in Illustration
      *1 Oil Filter Element
      *2 Oil Filter Cap
      *3 O-ring

      Remove the oil filter element and O-ring from the oil filter cap.

      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 SUB-ASSEMBLY


    1. A01EWEME03
      Text in Illustration
      *1 Nut

      Remove the 11 bolts and 2 nuts.

    2. A01EXJX

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

      Note


      • Be careful not to damage the stiffening crankcase contact surface of the oil pan.

      • Be careful not to damage the stiffening crankcase flange.

  50. REMOVE OIL STRAINER SUB-ASSEMBLY


    1. A01EVDX

      Remove the 3 bolts, oil strainer and gasket.

  51. REMOVE NO. 1 OIL PAN BAFFLE PLATE


    1. A01EYXR

      Remove the 5 bolts and oil pan baffle plate.

  52. INSPECT CRANKSHAFT BACKLASH


    1. A01EWJM

      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. A01EUHH

      Remove the 7 bolts and engine balancer.

      Note

      Do not disassemble the engine balancer.

  54. INSPECT BALANCE SHAFT THRUST CLEARANCE


    1. A01EWQO

      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.

  55. REMOVE STIFFENING CRANKCASE ASSEMBLY


    1. A01EYLP

      Remove the 7 bolts.

    2. A01EXHDE03
      Text in Illustration
      *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.

      Tech Tips

      Tape the screwdriver tip before use.

      Note

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

  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. A01EU7N

      Remove the rear engine oil seal from the cylinder block.