ENGINE UNIT DISASSEMBLY


  1. REMOVE OIL FILLER CAP SUB-ASSEMBLY


    1. A01EVBX

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

  2. REMOVE OIL FILLER CAP GASKET


    1. A01EX3S

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

  3. REMOVE VENTILATION VALVE SUB-ASSEMBLY


    1. A01EYFNE01
      Text in Illustration
      *1 Ball Joint Lock Nut Wrench (22 mm)

      Using a ball joint lock nut wrench (22 mm), remove the ventilation valve sub-assembly.

  4. REMOVE SPARK PLUG


    1. A01ESZQ

      Remove the 4 spark plugs.

  5. REMOVE OIL FILTER SUB-ASSEMBLY


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

      SST
      09228-06501

  6. REMOVE OIL FILTER UNION


    1. A01EV14

      Using a 12 mm socket hexagon wrench, remove the oil filter union.

  7. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A01ET0LE05
      Text in Illustration
      *a Nut

      Remove the 8 bolts and 2 nuts, and remove the cylinder head cover sub-assembly.

  8. REMOVE CYLINDER HEAD COVER GASKET


    1. A01EYAT

      Remove the cylinder head cover gasket from the cylinder head cover sub-assembly.

  9. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY


    1. A01EWJR

      Remove the bolt, nut and V-ribbed belt tensioner assembly.

  10. REMOVE CRANK POSITION SENSOR


    1. A01EX86

      Disconnect the 2 wire harness clamps.

    2. Remove the bolt and crank position sensor.

  11. REMOVE CAMSHAFT POSITION SENSOR


    1. A01EZ0H

      Remove the bolt and camshaft position sensor.

  12. SET NO. 1 CYLINDER TO TDC/COMPRESSION


    1. A01EVKIE02
      Text in Illustration
      *a Timing Mark
      *b Front Mark
      *c Groove

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

    2. Check that each timing mark on the camshaft timing gear assembly and camshaft timing sprocket with the front marks 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.

  13. REMOVE CRANKSHAFT PULLEY


    1. A01EUOOE01
      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   ( 91651-60855 )
      09330-00021
    2. A01EYMME01
      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, 09954-05021 )

      Tech Tips

      Apply a lubricant to the threads and end of SST.

  14. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY


    1. A01EUIP

      Remove the bolt and camshaft timing oil control valve assembly from the cylinder head sub-assembly.

      Note

      The camshaft timing oil control valve assembly may be damaged when loosening the cylinder head bolts if it is not removed.

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

  15. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY


    1. A01EUZW

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

      Note

      Do not turn the crankshaft without the No. 1 chain tensioner assembly.

  16. REMOVE WATER PUMP PULLEY


    1. A01EZ4OE03

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

      SST
      09960-10010   ( 09962-01000, 09963-00700 )

  17. REMOVE ENGINE WATER PUMP ASSEMBLY


    1. A01EY1JE03
      Text in Illustration
      *1 Wire Harness Clamp Bracket

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

    2. A01EY1KE03
      Text in Illustration
      *a Protective Tape

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

      Tech Tips

      Tape the screwdriver tip before use.

      Note

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

  18. REMOVE OIL PAN DRAIN PLUG


    1. A01ESP8

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

  19. REMOVE OIL PAN SUB-ASSEMBLY


    1. A01EUFT

      Remove the 12 bolts and 2 nuts.

    2. A01EXBT

      Insert the blade of an oil pan seal cutter between the crankcase, chain cover and oil pan, then cut through the applied sealer and remove the oil pan sub-assembly.

      Note

      Be careful not to damage the contact surfaces of the crankcase, chain cover or oil pan.

  20. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY


    1. A01EUWT

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

    2. Remove the 12 bolts and 2 nuts.

    3. A01EV3OE01
      Text in Illustration
      *1 Protective Tape

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

      Note

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

      Tech Tips

      Tape the screwdriver tip before use.

  21. REMOVE TIMING CHAIN COVER OIL SEAL


    1. A01EVOBE02
      Text in Illustration
      *1 Protective Tape

      Place the timing chain cover sub-assembly on wooden blocks.

    2. Using a screwdriver, 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.

  22. REMOVE NO. 1 CRANKSHAFT POSITION SENSOR PLATE


    1. A01EU63E01

      Remove the No. 1 crankshaft position sensor plate.

  23. REMOVE TIMING CHAIN GUIDE


    1. A01EWX3

      Remove the bolt and timing chain guide.

  24. REMOVE CHAIN TENSIONER SLIPPER


    1. A01EV4F

      Remove the bolt and chain tensioner slipper.

  25. REMOVE NO. 1 CHAIN VIBRATION DAMPER


    1. A01EUUP

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

  26. REMOVE CHAIN SUB-ASSEMBLY


    1. A01EY9XE01

      Remove the chain sub-assembly.

  27. REMOVE CRANKSHAFT TIMING SPROCKET


    1. A01EZ3R

      Remove the crankshaft timing sprocket from the crankshaft.

  28. REMOVE NO. 2 CHAIN SUB-ASSEMBLY


    1. A01EWYTE04
      Text in Illustration
      *1 Groove

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

    2. A01EUYWE04
      Text in Illustration
      *1 Groove

      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.

    3. A01ETIPE07
      Text in Illustration
      *1 Bolt
      *2 Chain Tensioner Plate
      *3 Chain Damper Spring

      Remove the bolt, chain tensioner plate and chain damper spring.

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

  29. REMOVE CRANKSHAFT PULLEY SET KEY


    1. A01ETLW

      Remove the 2 crankshaft pulley set keys from the crankshaft.

  30. REMOVE NO. 2 CAMSHAFT


    1. A01EWFLE01

      Using several steps, uniformly loosen and remove the 10 bearing cap bolts in the sequence shown in the illustration.

      Note

      Uniformly loosen the bolts while keeping the camshaft level.

      Tech Tips

      Arrange the removed parts in the correct order.

    2. Remove the 5 bearing caps.

    3. Remove the No. 2 camshaft.

  31. REMOVE CAMSHAFT


    1. A01EXRHE01

      Using several steps, uniformly loosen and remove the 10 bearing cap bolts in the sequence shown in the illustration.

      Note

      Uniformly loosen the bolts while keeping the camshaft level.

      Tech Tips

      Arrange the removed parts in the correct order.

    2. Remove the 5 bearing caps.

    3. Remove the camshaft.

  32. REMOVE NO. 1 CAMSHAFT BEARING


    1. A01ETI3

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

  33. REMOVE NO. 2 CAMSHAFT BEARING


    1. A01EUDR

      Remove the No. 2 camshaft bearing from the cylinder head sub-assembly.

  34. REMOVE CAMSHAFT TIMING SPROCKET


    1. A01EWB4E01

      Clamp the camshaft in a vise.

      Note


      • Do not overtighten the vise.

      • Do not damage the camshaft.

    2. Remove the bolt and camshaft timing sprocket.

  35. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY


    1. A01EYCQE06
      Text in Illustration
      *1 Vinyl Tape
      *2 Rubber Piece
      *a Open
      *b Close
      *c Advance Side Path

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

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

    3. A01EUJPE02

      Apply air pressure of 150 kPa (1.5 kgf/cm2, 22 psi) to the open 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.

      Tech Tips

      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. A01EW9DE06
      Text in Illustration
      *a Do Not Remove

      Remove the bolt and camshaft timing gear assembly.

      Note


      • Be sure not to remove the other 4 bolts.

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

  36. REMOVE CYLINDER HEAD SUB-ASSEMBLY


    1. A01EUV2E01

      Using a 10 mm bi-hexagon wrench, uniformly loosen the 10 cylinder head set bolts in the order shown in the illustration.

      Note

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

    2. Remove the 10 cylinder head set bolts and 10 plate washers.

      Note

      Be careful not to drop plate washers into the cylinder head sub-assembly.

    3. A01EWGW

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

      Note

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

  37. REMOVE CYLINDER HEAD GASKET


    1. A01EU4TE06

      Remove the cylinder head gasket.

  38. REMOVE CYLINDER BLOCK WATER JACKET SPACER


    1. A01EU57

      Using needle nose pliers, remove the cylinder block water jacket spacer from the water jacket.

      Note

      Before turning the cylinder block upside down, make sure that the water jacket spacer is removed, as it will fall out.

  39. REMOVE WATER INLET HOUSING


    1. A01ETQZE01

      Remove the 5 bolts in the order shown in the illustration to remove the water inlet housing from the cylinder block.

    2. A01EVA5E06
      Text in Illustration
      *1 Water Inlet Housing O-ring
      *2 Water Inlet Housing Gasket

      Remove the water inlet housing O-ring and water inlet housing gasket from the water inlet housing.

  40. REMOVE OIL CONTROL VALVE FILTER


    1. A01EV54E05
      Text in Illustration
      *1 Oil Control Valve Filter
      *2 Gasket
      *3 Screw Plug

      Using an 8 mm socket hexagon wrench, remove the screw plug, gasket and oil control valve filter.

  41. REMOVE NO. 1 TAPER SCREW PLUG


    1. A01EXBJ

      Remove the No. 1 taper screw plug from the cylinder block.

  42. REMOVE OIL PUMP ASSEMBLY


    1. A01EUZ7E01

      Remove the 3 bolts, oil pump assembly and oil pump gasket.

  43. INSPECT BALANCE SHAFT THRUST CLEARANCE


    1. Install the balance shafts Click here.

    2. A01EZ0I

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

  44. REMOVE BALANCE SHAFT HOUSING


    1. A01EXIJE01

      Using several steps, uniformly loosen and remove the 8 bolts in the sequence shown in the illustration.

    2. Remove the balance shaft housing from the stiffening crankcase assembly.

      Tech Tips

      Keep the lower bearing and balance shaft housing together.

  45. REMOVE NO. 1 AND NO. 2 BALANCE SHAFTS


    1. A01EW4JE08
      Text in Illustration
      *1 No. 1 Balance Shaft
      *2 No. 2 Balance Shaft

      Remove the No. 1 and No. 2 balance shafts.

  46. REMOVE NO. 1 BALANCE SHAFT BEARING


    1. A01EV6AE12
      Text in Illustration
      *1 Stiffening Crankcase
      *2 Balance Shaft Housing

      Remove the 8 No. 1 balance shaft bearings shown in the illustration.

  47. INSPECT BALANCE SHAFT 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 balance shaft.

    3. Place the No. 1 and No. 2 balance shafts onto the stiffening crankcase assembly.

    4. A01EWFAE02
      Text in Illustration
      *1 Plastigage

      Lay a strip of Plastigage across each journal.

    5. Install the balance shaft housing Click here.

      Note

      Do not turn the balance shafts.

    6. Remove the balance shaft housing Click here.

    7. A01EXZME03
      Text in Illustration
      *1 Plastigage

      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 balance shaft.

    8. A01EYQIE02
      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

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

      Standard Balance Shaft 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 balance shaft journal diameter
      22.985 to 23.000 mm (0.9049 to 0.9055 in.)

    9. Inspect the balance shaft housing bolts.


      1. A01EUHZE05
        Text in Illustration
        *a Measurement Length

        Using a vernier caliper, measure the length of the balance shaft housing 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 balance shaft housing bolt length is greater than the maximum, replace the balance shaft housing bolt.

  48. REMOVE REAR ENGINE OIL SEAL


    1. A01EYHOE09
      Text in Illustration
      *1 Protective Tape
      *a Cut Position

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

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

      Note


      • Tape the screwdriver tip before use.

      • Do not damage the surface of the rear engine oil seal press fit hole or the crankshaft.

  49. REMOVE STIFFENING CRANKCASE ASSEMBLY


    1. A01EY1YE01

      Uniformly loosen and remove the 11 bolts in the sequence shown in the illustration.

    2. A01EUM5E02
      Text in Illustration
      *a Protective Tape

      Using a screwdriver with its tip wrapped with protective tape, remove the stiffening crankcase assembly by prying between the stiffening crankcase assembly and cylinder block.

      Note

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