БЛОК ДВИГАТЕЛЯ РАЗБОРКА


  1. REMOVE NO. 4 WATER BY-PASS PIPE


    1. A01FSX5E02
      Text in Illustration
      *1 No. 4 Water By-pass Pipe
      *2 No. 9 Water By-pass Hose
      *3 No. 7 Water By-pass Hose
      *4 No. 8 Water By-pass Hose

      Slide the clip and disconnect the No. 9 water by-pass hose from the cylinder head sub-assembly.

    2. Slide the 2 clips and disconnect the No. 7 water by-pass hose and No. 8 water by-pass hose from the oil cooler assembly.

    3. Remove the 2 bolts and No. 4 water by-pass pipe.

  2. REMOVE SPARK PLUG


    1. Remove the 4 spark plugs from the cylinder head sub-assembly.

      Note

      If a spark plug has been struck or dropped, replace it.

      Tech Tips

      Arrange the removed parts in the correct order.

  3. REMOVE KNOCK CONTROL SENSOR


    1. A01FRLG

      Disconnect the knock control sensor connector.

    2. Remove the bolt and knock control sensor from the cylinder block sub-assembly.

  4. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY


    1. A01FV8L

      Disconnect the engine oil pressure switch assembly connector.

    2. Using a 24 mm deep socket wrench, remove the engine oil pressure switch assembly.

  5. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY


    1. for Exhaust Side:


      1. A01FS7Z

        Disconnect the camshaft timing oil control valve assembly connector.

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

        Note

        Do not allow foreign matter to contact the oil seal face of the camshaft timing oil control valve assembly (connecting surface with the cylinder head cover sub-assembly).

      3. A01FT9UE11
        Text in Illustration
        *1 O-ring

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

    2. for Intake Side:


      1. A01FQZ8

        Disconnect the camshaft timing oil control valve assembly connector.

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

        Note

        Do not allow foreign matter to contact the oil seal face of the camshaft timing oil control valve assembly (connecting surface with the cylinder head cover sub-assembly).

      3. A01FT9UE11
        Text in Illustration
        *1 O-ring

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

  6. REMOVE VVT SENSOR


    1. for Exhaust Side:


      1. A01FRFE

        Disconnect the VVT sensor connector.

      2. Remove the bolt and VVT sensor from the cylinder head cover sub-assembly.

    2. for Intake Side:


      1. A01FTNW

        Disconnect the VVT sensor connector.

      2. Remove the bolt and VVT sensor from the cylinder head cover sub-assembly.

  7. REMOVE PCV VALVE SUB-ASSEMBLY


    1. A01FSCW

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

  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 CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A01FQT9

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

      Text in Illustration
      A01FTNO Bolt
      A01FRJI Bolt with Seal Washer

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

    3. A01FRLSE01
      Text in Illustration
      *1 No. 1 Camshaft Bearing Cap
      *2 No. 2 Camshaft Bearing Cap

      Remove the 3 gaskets from the No. 1 camshaft bearing cap and No. 2 camshaft bearing cap.

  11. REMOVE PCV CASE SUB-ASSEMBLY


    1. A01FQG7

      Remove the gasket from the PCV case sub-assembly.

    2. A01FSCG

      Remove the 2 bolts and PCV case sub-assembly from the cylinder head cover sub-assembly.

    3. A01FTQEE03
      Text in Illustration
      *1 O-ring

      Remove the O-ring from the PCV case sub-assembly.

  12. REMOVE SPARK PLUG TUBE GASKET


    1. A01FVC2E02
      Text in Illustration
      *a Protective 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.

  13. REMOVE CRANKSHAFT POSITION SENSOR


    1. A01FS8Y

      Disconnect the crankshaft position sensor connector.

    2. Remove the bolt and crankshaft position sensor from the timing chain cover assembly.

  14. REMOVE CRANKSHAFT PULLEY ASSEMBLY


    1. A01FVX2E01
      Text in Illustration
      *a Hold
      *b Turn

      Using SST, hold the crankshaft pulley assembly and loosen the crankshaft pulley set bolt. Further loosen the crankshaft pulley set 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. A01FRMDE02
      Text in Illustration
      *1 Crankshaft Pulley Set Bolt
      *a Hold
      *b Turn

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

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

      Tech Tips

      Apply molybdenum grease to the threads and tip of SST (center bolt) prior to use.

  15. REMOVE TIMING CHAIN COVER ASSEMBLY


    1. A01FT8H

      Remove the 19 bolts and 3 nuts from the timing chain cover assembly.

      Text in Illustration
      A01FTNO Bolt
      A01FRJI Nut

    2. Remove the timing chain cover assembly by prying between the timing chain cover assembly and camshaft housing sub-assembly, stiffening crankcase assembly, cylinder block sub-assembly or cylinder head sub-assembly with a screwdriver.

      Note

      Be careful not to damage the contact surfaces of the timing chain cover assembly, camshaft housing sub-assembly, stiffening crankcase assembly, cylinder block sub-assembly and cylinder head sub-assembly.

      Tech Tips

      Tape the screwdriver tip before use.

      A01FVAAE01
      Text in Illustration
      *a Protective Tape - -
    3. A01FS9V

      Remove the gasket from the cylinder head sub-assembly.

    4. A01FTCG

      Remove the 2 gaskets from the stiffening crankcase assembly and oil strainer sub-assembly.

  16. REMOVE TIMING CHAIN COVER PLATE


    1. A01FU07

      Remove the 4 bolts, timing chain cover plate and No. 1 timing belt cover gasket from the timing chain cover assembly.

  17. REMOVE TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL


    1. A01FVL7E01
      Text in Illustration
      *a Protective Tape
      *b Wooden Block

      Using a screwdriver and wooden block, pry out the timing gear case or timing chain case oil seal.

      Note

      Do not damage the surface of the timing gear case or timing chain case oil seal press fit hole.

      Tech Tips

      Tape the screwdriver tip before use.

  18. SET NO. 1 CYLINDER TO TDC/COMPRESSION


    1. Temporarily install the crankshaft pulley set bolt.

    2. Rotate the crankshaft clockwise so that the timing marks on the crankshaft timing gear or sprocket and camshaft timing gears are positioned as shown in the illustration.

      A01FU0NE02
      Text in Illustration
      *1 Crankshaft Pulley Set Crankshaft Key - -
      *a Timing Mark *b Identification Groove
      *c Approximately 7° *d Approximately 32°

      Tech Tips


      • The camshaft timing gear assembly and the camshaft timing exhaust gear assembly have both timing marks and identification grooves. Use the timing marks for alignment.

      • If the timing marks do not align, rotate the crankshaft clockwise again and align the timing marks.

    3. Remove the crankshaft pulley set bolt.

  19. REMOVE TIMING CHAIN GUIDE


    1. A01FV2E

      Remove the bolt and timing chain guide.

  20. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY


    1. A01FTUYE02
      Text in Illustration
      *a Stopper Plate
      *b 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. A01FSQ0E02
      Text in Illustration
      *a Pin

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

    3. A01FQNA

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

  21. REMOVE CHAIN TENSIONER SLIPPER


    1. A01FUDW

      Remove the bolt and chain tensioner slipper.

  22. REMOVE NO. 1 CHAIN VIBRATION DAMPER


    1. A01FSFU

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

  23. REMOVE CHAIN SUB-ASSEMBLY


    1. Remove the chain sub-assembly.

  24. REMOVE CRANKSHAFT TIMING GEAR OR SPROCKET


    1. A01FSVS

      Remove the crankshaft timing gear or sprocket from the crankshaft.

  25. REMOVE CRANKSHAFT PULLEY SET CRANKSHAFT KEY


    1. A01FQ2PE02
      Text in Illustration
      *a Protective Tape

      Using a screwdriver, remove the 2 crankshaft pulley set crankshaft keys from the crankshaft.

      Tech Tips

      Tape the screwdriver tip before use.

  26. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY


    1. A01FQ2ZE01
      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


      • Never remove the 4 bolts (A). If they are removed, make sure to replace the camshaft timing gear assembly.

      • Be careful not to damage the camshaft housing sub-assembly or spark plug tube with the wrench.

    2. Remove the camshaft timing gear assembly from the camshaft.

  27. REMOVE CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY


    1. A01FTENE02
      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


      • Never remove the 4 bolts (A). If they are removed, make sure to replace the camshaft timing exhaust gear assembly.

      • Be careful not to damage the camshaft housing sub-assembly or spark plug tube with the wrench.

    2. Remove the camshaft timing exhaust gear assembly from the No. 2 camshaft.

  28. REMOVE OIL PIPE SUB-ASSEMBLY


    1. A01FQN4

      Remove the bolt and oil pipe sub-assembly from the No. 4 camshaft bearing cap.

  29. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY


    1. A01FU1AE01

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

    2. A01FTK9

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

      Note

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

      Tech Tips

      Tape the screwdriver tip before use.

  30. REMOVE CAMSHAFT BEARING CAP


    1. A01FV6RE03
      Text in Illustration
      *1 No. 1 Camshaft Bearing Cap
      *2 No. 2 Camshaft Bearing Cap
      *3 No. 3 Camshaft Bearing Cap
      *4 No. 4 Camshaft Bearing Cap

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

    2. Remove the No. 1 camshaft bearing cap, No. 2 camshaft bearing cap, No. 3 camshaft bearing cap and No. 4 camshaft bearing cap.

  31. REMOVE OIL CONTROL VALVE FILTER


    1. A01FQXD

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

      Note

      Do not touch the mesh section on the oil control valve filter.

  32. REMOVE NO. 1 CAMSHAFT BEARING


    1. A01FV3W

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

  33. REMOVE CAMSHAFT


    1. Remove the camshaft from the camshaft housing sub-assembly.

  34. REMOVE NO. 2 CAMSHAFT


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

  35. REMOVE NO. 2 CAMSHAFT BEARING


    1. A01FQLG

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

  36. 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

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

  37. REMOVE VALVE LASH ADJUSTER ASSEMBLY


    1. Remove the 16 valve lash adjuster assemblies from the cylinder head sub-assembly.

      Tech Tips

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

  38. REMOVE VALVE STEM CAP


    1. Remove the 16 valve stem caps from the valve stem ends.

      Tech Tips

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

  39. REMOVE CYLINDER HEAD SUB-ASSEMBLY


    1. A01FQXUE01

      Using a 10 mm bi-hexagon wrench, uniformly loosen the 10 cylinder head set bolts in the sequence shown in the illustration. Remove the 10 cylinder head set bolts and plate washers.

      Note


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

      • Cylinder head sub-assembly warpage or cracking could result from removing cylinder head set bolts in an incorrect order.

      Tech Tips

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

    2. Remove the cylinder head sub-assembly.

  40. REMOVE CYLINDER HEAD GASKET


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

  41. REMOVE CYLINDER BLOCK WATER JACKET SPACER


    1. A01FUDP

      Remove the cylinder block water jacket spacer from the cylinder block sub-assembly.

      Note

      Be sure to remove the water jacket spacer. If it is not removed, it may fall and become damaged when the cylinder block sub-assembly is inverted.

  42. REMOVE OIL FILTER CAP ASSEMBLY


    1. A01FQZME10
      Text in Illustration
      *a Pipe
      *b Hose

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

    2. A01FRCW

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

    3. A01FU83E01
      Text in Illustration
      *1 Oil Filter Cap Assembly
      *2 O-Ring
      *a Pipe
      *b Hose

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

      Note

      Be sure to insert the pipe with hose with the O-ring installed on the oil filter cap assembly.

      Tech Tips

      Place the hose end into a container before draining the engine oil from the hose.

    4. A01FV99

      Make sure that the engine oil is completely drained, and remove the pipe with hose and O-ring.

      Tech Tips

      Be sure to turn the pipe in the direction of the arrow to remove it.

    5. A01FVFNE01
      Text in Illustration
      *1 Oil Filter Bracket Clip

      Using SST, remove the oil filter cap assembly from the stiffening crankcase assembly.

      SST
      09228-06501

      Note

      Do not remove the oil filter bracket clip when removing the oil filter cap assembly.

    6. A01FV89E01
      Text in Illustration
      *1 Oil Filter Element
      *2 O-Ring

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

      Note

      Do not use any tools to remove the O-ring to prevent damage to the oil filter cap assembly. Be sure to remove it by hand.

  43. REMOVE ENGINE OIL LEVEL SENSOR


    1. A01FSHI

      Disconnect the engine oil level sensor connector.

    2. Remove the 4 bolts and engine oil level sensor.

    3. A01FTSGE01
      Text in Illustration
      *a Cutting Position
      *b Supply Part

      Cut away part of the gasket and remove the gasket from the engine oil level sensor.

      Tech Tips

      Remove only the outer part of the gasket.

  44. REMOVE OIL COOLER ASSEMBLY


    1. A01FVR3E01
      Text in Illustration
      *1 No. 7 Water By-pass Hose
      *2 No. 8 Water By-pass Hose

      Slide the clamp and disconnect the No. 7 water by-pass hose from the oil cooler assembly.

      Note

      Spray lubricant agent between the oil cooler assembly pipe and No. 7 water by-pass hose so that the No. 7 water by-pass hose can be disconnected easily.

      Tech Tips

      Use a cloth to prevent lubricant agent from spattering.

    2. Slide the clamp and disconnect the No. 8 water by-pass hose from the oil cooler assembly.

      Note

      Spray lubricant agent between the oil cooler assembly pipe and No. 8 water by-pass hose so that the No. 8 water by-pass hose can be disconnected easily.

      Tech Tips

      Use a cloth to prevent lubricant agent from spattering.

    3. A01FUHT

      Remove the 2 nuts, 2 bolts and oil cooler assembly.

      Text in Illustration
      A01FTNO Bolt
      A01FRJI Nut
    4. A01FU9E

      Remove the 2 O-rings from the stiffening crankcase assembly.

  45. REMOVE OIL PAN DRAIN PLUG


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

  46. REMOVE OIL PAN SUB-ASSEMBLY


    1. A01FTHK

      Remove the 11 bolts and 2 nuts.

      Text in Illustration
      A01FTNO Bolt
      A01FRJI Nut
    2. A01FUAWE04
      Text in Illustration
      *a Oil Pan Seal Cutter

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

      • Be careful not to damage the oil pan sub-assembly flange.

      Tech Tips

      Be sure to clean the bolts and stud bolts and check the threads for cracks or other damage.

  47. REMOVE OIL STRAINER SUB-ASSEMBLY


    1. A01FRWU

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

  48. REMOVE NO. 1 OIL PAN BAFFLE PLATE


    1. A01FR1S

      Remove the 4 bolts and No. 1 oil pan baffle plate.

  49. REMOVE ENGINE BALANCER ASSEMBLY


    1. A01FT50

      Remove the 5 bolts and engine balancer assembly.

      Note

      Do not disassemble the engine balancer assembly.

  50. REMOVE STIFFENING CRANKCASE ASSEMBLY


    1. A01FQ4P

      Remove the 7 bolts.

    2. A01FTBDE01
      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


      • Do not pry section A in the illustration. Otherwise, the stiffening case assembly may be damaged.

      • 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.

  51. REMOVE REAR ENGINE OIL SEAL


    1. A01FSU1

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

  52. REMOVE STUD BOLT

    Note

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

  53. REMOVE CYLINDER HEAD SUB-ASSEMBLY

    Note

    If a ring pin is deformed or damaged, replace it.

  54. REMOVE STRAIGHT PIN

    Note

    If a straight pin is deformed or damaged, replace it.