БЛОК ДВИГАТЕЛЯ РАЗБОРКА

Tech Tips


  • Thoroughly clean all parts to be assembled.

  • Before installing the parts, apply new engine oil to all sliding and rotating surfaces.

  • Replace all gaskets, O-rings and oil seals with new parts.


  1. REMOVE NO. 1 ENGINE HANGER


    1. A01DYDFE01

      Remove the 2 bolts and No. 1 engine hanger.

  2. REMOVE NO. 2 ENGINE HANGER


    1. Remove the 2 bolts and No. 2 engine hanger.

  3. REMOVE OIL DIPSTICK GUIDE


    1. Remove the bolt and pull out the oil dipstick.

    2. Remove the O-ring from the oil level gauge guide.

  4. REMOVE CYLINDER BLOCK WATER DRAIN COCK


    1. Remove the cylinder block water drain cock.

  5. REMOVE VVT SENSOR


    1. Remove the 2 bolts and 2 sensors.

  6. REMOVE CRANKSHAFT POSITION SENSOR


    1. Remove the bolt and crankshaft position sensor.

  7. REMOVE OIL CONTROL VALVE FILTER


    1. A01DYOGE01

      Remove the plug, filter and gasket from each cylinder head.

  8. REMOVE CYLINDER HEAD COVER RH


    1. A01DY80E01

      Remove the 10 bolts, 3 seal washers, 2 nuts, head cover and gasket.

  9. REMOVE CYLINDER HEAD COVER LH


    1. A01DXX5E01

      Remove the 10 bolts, 3 seal washers, 2 nuts, cylinder head cover and gasket.

    2. Remove the ventilation valve from the cylinder head cover.

  10. REMOVE CRANKSHAFT PULLEY


    1. A01DYXVE01

      Turn the crankshaft pulley, and align its groove with the timing mark 0 of the timing chain cover.

    2. A01DVC1E03

      Check that the timing marks of the camshaft timing gears are aligned with the timing marks of the bearing cap as shown in the illustration.

      If not, turn the crankshaft 1 revolution (360°) and align the timing marks as above.

    3. A01DWJLE01

      Using SST, hold the crankshaft pulley and loosen the pulley set bolt.

      SST
      09213-54015   ( 91651-60855 )
      09330-00021
    4. A01DX9BE01

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

      SST
      09950-50013   ( 09951-05010, 09952-05010, 09953-05020, 09954-05030 )

  11. REMOVE OIL PAN DRAIN PLUG


    1. Remove the drain plug and gasket.

  12. REMOVE NO. 2 OIL PAN


    1. A01E0H4E01

      Remove the 14 bolts and 2 nuts.

    2. A01DX7D

      Insert the blade of an oil pan seal cutter between the oil pan and No. 2 oil pan, cut through the applied sealer and remove the No. 2 oil pan.

      Note


      • Be careful not to damage the contact surface of the No. 2 oil pan and oil pan.

      • Be careful not to damage the No. 2 oil pan flange.

  13. REMOVE OIL STRAINER


    1. A01DVQ4

      Remove the 2 nuts, oil strainer and gasket.

  14. REMOVE NO. 1 OIL PAN


    1. A01DZ7NE02

      Remove 17 bolts and 2 nuts.

    2. A01DWRB

      Using a screwdriver, remove the oil pan by prying between the oil pan and cylinder block in the sequence shown.

      Note

      Be careful not to damage the contact surfaces of the cylinder block and oil pan.

    3. Remove the O-ring from the timing chain cover.

  15. REMOVE WATER PUMP


    1. A01DW3QE02

      Remove the 17 bolts, water pump and gasket.

  16. REMOVE TIMING CHAIN COVER


    1. A01DYG2E01

      Remove the 15 bolts and 2 nuts.

    2. A01DYR1E01

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

      Note

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

    3. Remove the O-ring from the LH cylinder head.

  17. REMOVE NO. 1 CHAIN TENSIONER

    A01DYZTE01

    Note


    • Never rotate the crankshaft with the chain tensioner removed.

    • When rotating the camshaft with the timing chain removed, rotate the crankshaft counterclockwise 40° from the TDC before rotating it.


    1. While rotating the stopper plate of the tensioner upward, push in the plunger of the chain tensioner as shown in the illustration.

    2. While rotating the stopper plate of the tensioner downward, insert a bar of diameter of 3.5 mm (0.138 in.) into the holes in the stopper plate and tensioner to fix the stopper plate.

    3. Remove the 2 bolts and chain tensioner.

  18. REMOVE CHAIN TENSIONER SLIPPER

  19. REMOVE NO. 1 IDLE GEAR


    1. A01DZXQE01

      Using a 10 mm hexagon wrench, remove the No. 2 idle gear shaft, No. 1 idle gear and No. 1 idle gear shaft.

  20. REMOVE NO. 2 VIBRATION DAMPER


    1. A01E1K7E01

      Remove the 2 chain vibration dampers.

  21. REMOVE CHAIN

  22. REMOVE CRANKSHAFT TIMING SPROCKET

  23. REMOVE NO. 1 CHAIN VIBRATION DAMPER


    1. A01DWH2E01

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

  24. REMOVE CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (RH BANK)


    1. A01DZYKE01

      While raising up the No. 2 chain tensioner, insert a pin of diameter of 1.0 mm (0.039 in.) into the hole to fix it.

    2. A01DXUWE01

      Hold the hexagonal portion of the camshaft with a wrench, and remove the 2 bolts, camshaft timing gear, camshaft timing gear assembly and No. 2 timing chain.

      Note


      • Be careful not to damage the cylinder head and valve lifter with the wrench.

      • Do not disassemble the camshaft timing gear assembly.

  25. REMOVE NO. 2 CHAIN TENSIONER


    1. A01E0WLE01

      Remove the bolt and No. 2 chain tensioner.

  26. REMOVE CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (LH BANK)


    1. A01DZWRE01

      While pushing down the No. 3 chain tensioner, insert a pin of diameter of 1.0 mm (0.039 in.) into the hole to fix it.

    2. A01DYILE01

      Hold the hexagonal portion of the camshaft with a wrench, and remove the 2 bolts, camshaft timing gear, camshaft timing gear assembly and No. 2 timing chain.

      Note


      • Be careful not to damage the cylinder head and valve lifter with the wrench.

      • Do not disassemble the camshaft timing gear assembly.

  27. REMOVE NO. 3 CHAIN TENSIONER


    1. A01E1YCE01

      Remove the bolt and No. 3 chain tensioner.

  28. REMOVE CAMSHAFT

    Note

    As the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being removed. If the camshaft is not kept level, the portion of the cylinder head which received the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, the following steps should be carried out.


    1. A01E2YME01

      Remove the camshafts of the RH bank.


      1. Rotate the camshafts counterclockwise using hexagonal portion of the each camshaft so that the cam lobes of the No. 1 cylinder may face as shown in the illustration.

      2. A01DXZRE03

        Uniformly loosen and remove the 16 bearing cap bolts in several passes, in the sequence shown.

      3. Remove the 8 bearing caps and 2 camshafts.

    2. A01DWU1E03

      Remove the camshafts of the LH bank.


      1. Uniformly loosen and remove the 16 bearing cap bolts in several passes, in the sequence shown.

      2. Remove the 8 bearing caps and 2 camshafts.

  29. REMOVE NO. 1 CAMSHAFT BEARING

  30. REMOVE NO. 2 CAMSHAFT BEARING

  31. REMOVE CYLINDER HEAD


    1. A01DYX3E01

      Remove the 2 cylinder head bolts on the LH cylinder head in several passes, in the sequence shown.

    2. A01DXTPE02

      Using a 10 mm bi-hexagon wrench, uniformly loosen the 8 cylinder head bolts on each cylinder head, in several passes, in the sequence shown, then repeat for the other side as shown. Remove the 16 cylinder head bolts and plate washers.

      Note


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

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

    3. A01DWXAE01

      Lift the cylinder head from the dowels on the cylinder block, and place the 2 cylinder heads on wooden blocks on a bench.

      Note

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

      Tech Tips

      If the cylinder head is difficult to lift off, pry between the cylinder head and cylinder block with a screwdriver.

    4. Remove the RH and LH cylinder head gaskets.

  32. REMOVE NO. 1 WATER OUTLET PIPE


    1. A01DZJOE01

      Separate the knock sensor wire.

    2. Remove the bolt, 2 nuts and water outlet pipe.

  33. REMOVE KNOCK SENSOR


    1. A01E2ZYE01

      Disconnect the knock sensor connectors.

    2. Remove the 2 bolts and 2 knock sensors.

  34. REMOVE ENGINE REAR OIL SEAL RETAINER


    1. A01E0Y2E01

      Remove the 5 bolts and 2 nuts.

    2. Using a screwdriver, remove the oil seal retainer by prying the portions between the oil seal retainer and crankshaft bearing cap.

  35. REMOVE VALVE LIFTER

    A01DVARE01

    Tech Tips

    Arrange the valve lifter in the correct order.

  36. REMOVE VALVE

    A01DWX8E01

    Tech Tips

    Arrange the valves, inner compression springs, valve spring retainers and valve spring retainer rocks in the correct order.


    1. Place the cylinder head on the wooden block.

    2. Using SST, compress the inner compression spring and remove the 2 valve spring retainer locks.

      SST
      09202-70020   ( 09202-00010 )

    3. Remove the valve, inner compression spring and valve spring and valve spring retainer.

  37. REMOVE VALVE SPRING SEAT


    1. A01E1UFE01

      Using compressed air and a magnet hand, remove the valve spring seat by blowing air.

  38. REMOVE VALVE STEM OIL SEAL


    1. A01E0JTE01

      Using a needle-nose pliers, remove the valve stem oil seal.

  39. CLEAN CYLINDER HEAD


    1. A01E324E01

      Using a gasket scraper, remove all the gasket material from the cylinder block contact surface.

      Note

      Be careful not to scratch the cylinder block contact surface.

    2. A01DW9QE01

      Using a wire brush, remove all the carbon from the combustion chambers.

      Note

      Be careful not to scratch the combustion chambers.

    3. A01E2JJE01

      Using a valve guide bushing brush and solvent, clean all the valve guide bushes.

    4. A01DYOOE01

      Using a soft brush and solvent, thoroughly clean the cylinder head.

  40. CLEAN VALVE


    1. A01DWPWE01

      Using a gasket scraper, chip off any carbon from the valve head.

    2. Using a wire brush, thoroughly clean the valve.

  41. REMOVE CONNECTING ROD CAP


    1. Using SST, remove the 2 connecting rod cap bols.

      SST
      09011-38121

    2. Remove the connecting rod cap.

  42. REMOVE PISTON WITH CONNECTING ROD


    1. A01DWPQE01

      Using a ridge reamer, remove all the carbon from the top of the cylinder.

    2. Push the piston, connecting rod assembly and upper bearing through the top of the cylinder block.

      Tech Tips


      • Keep the bearings, connecting rod and cap together.

      • Arrange the piston and connecting rod assemblies in the correct order.

  43. REMOVE PISTON RING SET


    1. A01DZDRE01

      Using a piston ring expander, remove the 2 compression rings.

    2. Remove the 2 side rails and oil ring by hand.

  44. REMOVE PISTON PIN HOLE SNAP RING


    1. A01DZP6E01

      Using a small screwdriver, pry out the 2 snap rings.

  45. REMOVE PISTON WITH PIN


    1. A01DVKJE05

      Gradually heat the piston to approximately 80°C (176°F).

    2. A01E0L8E01

      Using a plastic-faced hammer and brass bar, lightly tap out the piston pin and remove the connecting rod.

      Tech Tips


      • The piston and pin are a matched set.

      • Arrange the pistons, pins, rings, connecting rods and bearings in the correct order.

  46. REMOVE CRANKSHAFT


    1. A01DUX2E02

      Uniformly loosen and remove the 8 main bearing cap bolts and seal washers in the several passes, in the sequence shown.

    2. A01E0QHE02

      Uniformly loosen and remove the 16 main bearing cap bolts in several passes, in the sequence shown.

    3. A01DVCPE01
      A01E0HBE01

      Using a screwdriver, pry out main bearing caps. Remove the 4 main bearing caps and lower bearings.

      Note


      • Pull up the main bearing cap little by little to the right and the left by turns.

      • Be careful not to damage the joint surface of the cylinder block and the main bearing cap.

  47. REMOVE CRANKSHAFT THRUST WASHER SET

  48. REMOVE CRANKSHAFT BEARING

  49. REMOVE OIL NOZZLE


    1. A01DXN3E01

      Using a 5 mm socket hexagon wrench, remove the 3 oil nozzles.

  50. REMOVE TAPER SCREW PLUG

    Note

    It is not necessary to remove a taper screw plug unless it is being replaced.