ENGINE UNIT DISASSEMBLY

  1. REMOVE ENGINE COVER JOINT

    1. Remove the 3 engine cover joints.

      A011VY9

  2. REMOVE SPARK PLUG

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

      A011X2B

  3. REMOVE KNOCK CONTROL SENSOR

    1. Disconnect the sensor connector.

      A011VTN

    2. Remove the bolt and knock control sensor.

  4. REMOVE ENGINE COOLANT TEMPERATURE SENSOR

    1. Disconnect the ventilation hose from the cylinder head cover.

      A011VL0

    2. Disconnect the engine coolant temperature sensor connector.

      A011VPM

    3. Remove the 2 bolts and disconnect the wire harness.

    4. Using a 19 mm ball joint lock nut wrench, remove the engine coolant temperature sensor.

      A011WESE01
      Text in Illustration
      *1 Ball Joint Lock Nut Wrench
      *2 Gasket

    5. Remove the gasket from the engine coolant temperature sensor.

  5. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY

    1. Disconnect the connector.

      A011Z1W

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

  6. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY

    1. Disconnect the oil control valve connector.

      A011VFT

    2. Remove the bolt and oil control valve.

    3. Remove the O-ring from the oil control valve.

      A011Z2NE06
      Text in Illustration
      *1 O-ring

  7. REMOVE CAMSHAFT POSITION SENSOR

    1. Disconnect the sensor connector.

      A011W29

    2. Remove the bolt and sensor.

  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 CRANKSHAFT POSITION SENSOR

    A011YJB

    1. Disconnect the sensor connector.

    2. Remove the bolt and sensor.

  11. REMOVE VENTILATION VALVE SUB-ASSEMBLY

    1. Remove the No. 2 ventilation hose.

      A011VI6

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

      A011VI1E02
      Text in Illustration
      *1 19 mm Deep Socket Wrench

  12. REMOVE VENTILATION CASE SUB-ASSEMBLY

    1. Remove the 8 bolts and 2 nuts.

      A011Z45

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

      A011YVS

      Note

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

      Tech Tips

      Tape the screwdriver tip before use.

  13. REMOVE SEPARATOR CASE

    1. Remove the 2 bolts, separator case and gasket.

      A011Z3P

  14. REMOVE CRANKSHAFT PULLEY

    1. 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.

      A011VOBE06
      Text in Illustration
      *a Hold
      *b Turn
      SST
      09213-54015
      09330-00021
      91551-80650

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

      A011WOSE04
      Text in Illustration
      *1 Pulley Bolt
      *a Hold
      *b Turn
      SST
      09950-50013   ( 09951-05010, 09952-05010, 09953-05020, 09954-05011 )

      Tech Tips

      Apply a lubricant to the threads and end of SST.

  15. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY

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

      A011WWF

    2. Remove the 2 gaskets from the camshaft bearing caps.

      A011XD2

  16. REMOVE STUD BOLT

    Note

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

    1. Using an E6 "TORX" socket wrench, remove the 3 stud bolts from the cylinder head cover sub-assembly.

      A011YUL

  17. REMOVE SPARK PLUG TUBE GASKET

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

      A011WZ7E01
      Text in Illustration
      *1 Tape

      Note

      Be careful not to damage the cylinder head cover.

      Tech Tips

      Tape the screwdriver tip before use.

  18. REMOVE ENGINE MOUNTING BRACKET RH

    1. Remove the 5 bolts and engine mounting bracket RH.

      A011WYQ

  19. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY

    1. Remove the 17 bolts and 2 nuts.

      A011X8D

    2. 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.

      A011XPQE03
      Text in Illustration
      *1 Protective Tape

      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. Remove the 3 gaskets from the stiffening crankcase.

      A011XAW

  20. REMOVE OIL PUMP RELIEF VALVE PLUG

    1. Using a 14 mm hexagon wrench, remove the oil pump relief valve plug and gasket.

      A011XZ9

  21. REMOVE TIMING CHAIN COVER PLATE

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

      A011XXZ

  22. REMOVE TIMING CHAIN COVER OIL SEAL

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

      A011Z67E03
      Text in Illustration
      *1 Protective Tape
      *2 Wooden Block

      Note

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

      Tech Tips

      Tape the screwdriver tip before use.

  23. SET NO. 1 CYLINDER TO TDC/COMPRESSION

    1. Temporarily install the crankshaft pulley bolt.

      A011WSEE05
      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.

  24. REMOVE TIMING CHAIN GUIDE

    1. Remove the bolt and timing chain guide.

      A011WV8

  25. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY

    1. 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.

      A011WD5E02
      Text in Illustration
      *1 Stopper Plate
      *2 Plunger

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

      A011WE0E02
      Text in Illustration
      *1 Pin

    3. Remove the 2 bolts, chain tensioner and gasket.

      A011WRB

  26. REMOVE CHAIN TENSIONER SLIPPER

    1. Remove the bolt and chain tensioner slipper.

      A011YTL

  27. REMOVE CHAIN SUB-ASSEMBLY

    1. Remove the chain sub-assembly.

  28. REMOVE NO. 1 CHAIN VIBRATION DAMPER

    1. Remove the 2 bolts and chain vibration damper.

      A011W24

  29. REMOVE CRANKSHAFT TIMING SPROCKET

    1. Remove the crankshaft timing sprocket from the crankshaft.

      A011VCY

  30. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY

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

      A011VDOE02
      Text in Illustration
      *a Hold
      *b Turn

      Note

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

      • Do not disassemble the camshaft timing gear.

  31. REMOVE CAMSHAFT TIMING SPROCKET

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

      A011YDIE02
      Text in Illustration
      *a Hold
      *b Turn

      Note

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

  32. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY

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

      A011VUHE03

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

      A011WZE

      Tech Tips

      Tape the screwdriver tip before use.

      Note

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

  33. REMOVE CAMSHAFT BEARING CAP

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

      A011YJKE03

    2. Remove the 5 bearing caps.

      Tech Tips

      Arrange the removed parts in the correct order.

  34. REMOVE OIL CONTROL VALVE FILTER

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

      A011XGR

  35. REMOVE CAMSHAFT

    1. Remove the camshaft and No. 2 camshaft.

  36. REMOVE NO. 1 CAMSHAFT BEARING

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

      A011XAI

  37. REMOVE NO. 2 CAMSHAFT BEARING

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

      A011WIG

  38. REMOVE STUD BOLT

    Note

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

    1. Using an E8 "TORX" socket wrench, remove the stud bolt from the camshaft housing sub-assembly.

      A011YDT

  39. REMOVE CAMSHAFT BEARING CAP SETTING RING PIN

    Note

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

    1. Remove the 10 camshaft bearing cap setting ring pins from the camshaft housing sub-assembly.

      A011XXO

  40. REMOVE STRAIGHT PIN

    Note

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

    1. Remove the 2 straight pins from the camshaft housing sub-assembly.

      A011W4U

  41. 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.

  42. 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.

  43. 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.

  44. REMOVE CYLINDER HEAD SUB-ASSEMBLY

    1. 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.

      A011YOKE01

      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.

  45. REMOVE CYLINDER HEAD GASKET

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

  46. REMOVE CYLINDER BLOCK WATER JACKET SPACER

    1. Remove the cylinder block water jacket spacer from the cylinder block.

      A011XEN

      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.

  47. REMOVE OIL FILTER CAP ASSEMBLY

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

      A011WXXE06
      Text in Illustration
      *1 Pipe
      *2 Hose

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

      A011X92

    3. Install the pipe to the oil filter cap assembly.

      A011XX6E01
      Text in Illustration
      *1 Valve
      *2 Cap
      *3 O-ring
      *4 Pipe

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

      A011XDO

    5. Using SST, remove the oil filter cap assembly.

      A011WM7E01
      Text in Illustration
      *1 Oil Filter Bracket Clip
      SST
      09228-06501

      Note

      Do not remove the oil filter bracket clip.

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

      A011WC8E07
      Text in Illustration
      *1 Oil Filter Element
      *2 Oil Filter Cap Assembly
      *3 O-ring

      Note

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

  48. REMOVE OIL PAN DRAIN PLUG

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

  49. REMOVE OIL PAN SUB-ASSEMBLY

    1. Remove the 11 bolts and 2 nuts.

      A011XM2E03
      Text in Illustration
      *1 Nut

    2. 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.

      A011VLU

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

      A011XEH

  51. REMOVE NO. 1 OIL PAN BAFFLE PLATE

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

      A011YQA

  52. INSPECT CRANKSHAFT BACKLASH

    1. Using a dial indicator, measure the backlash of the crankshaft and balance shaft as shown in the illustration.

      A011YEF
      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. Remove the 7 bolts and engine balancer assembly.

      A011XBQ

      Note

      Do not disassemble the engine balancer.

  54. INSPECT NO. 1 BALANCE SHAFT THRUST CLEARANCE

    1. Using a dial indicator, measure the thrust clearance while moving the No. 1 balance shaft back and forth.

      A011Z2S
      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. INSPECT NO. 2 BALANCE SHAFT THRUST CLEARANCE

    1. Using a dial indicator, measure the thrust clearance while moving the No. 2 balance shaft back and forth.

      A011WGQ
      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. Remove the 7 bolts.

      A011X3L

    2. Using a screwdriver, remove the stiffening crankcase by prying between the stiffening crankcase and cylinder block at the places shown in the illustration.

      A011YJME03
      Text in Illustration
      *a LH Side:
      *b RH Side:

      Note

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

      Tech Tips

      Tape the screwdriver tip before use.

  57. REMOVE STUD BOLT

    Note

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

    1. Using an E5 and E8 "TORX" socket wrench, remove the 3 stud bolts from the stiffening crankcase assembly.

      A011YP0

  58. REMOVE RING PIN

    Note

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

    1. Remove the 2 ring pins from the stiffening crankcase assembly.

      A011X2D

  59. REMOVE REAR ENGINE OIL SEAL

    1. Remove the rear engine oil seal from the cylinder block.

      A011W23