ENGINE UNIT DISASSEMBLY

PROCEDURE

  1. REMOVE ENGINE COVER JOINT

    1. A259127

      Remove the 3 engine cover joints.

  2. REMOVE SPARK PLUG

    Click here

  3. REMOVE KNOCK CONTROL SENSOR

    Click here

  4. REMOVE ENGINE COOLANT TEMPERATURE SENSOR

    Click here

  5. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY

    Click here

  6. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY

    Click here

  7. REMOVE CAMSHAFT POSITION SENSOR

    Click here

  8. REMOVE OIL FILLER CAP SUB-ASSEMBLY

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

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

  9. REMOVE CRANKSHAFT POSITION SENSOR

    Click here

  10. REMOVE PCV VALVE

    Click here

  11. REMOVE PCV CASE

    1. A210185

      Remove the 8 bolts and 2 nuts.

    2. A210186

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

      Note:

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

      Tip:

      Tape the screwdriver tip before use.

  12. REMOVE SEPARATOR CASE

    1. A210188

      Remove the 2 bolts, separator case and gasket.

  13. REMOVE CRANKSHAFT PULLEY

    1. A311103C01

      *a

      Hold
      V100135

      Turn

      Using SST, hold the crankshaft pulley and loosen the pulley bolt until 2 or 3 threads are screwed into the crankshaft.

      09213-54015

      09330-00021

      Tip:

      Part number of installation bolt for SST (crankshaft pulley holding tool): 91551-80650 (quantity: 2)

    2. A328500C01

      *1

      Crankshaft Pulley Bolt

      *a

      Hold
      V100135

      Turn

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

      09950-50013

      09951-05010

      09952-05010

      09953-05020

      09954-05011

      09957-04010

      Tip:

      Apply lubricant to the threads and end of SST.

  14. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY

    1. A259132

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

    2. A259133

      Remove the 2 gaskets from the camshaft bearing caps.

  15. REMOVE SPARK PLUG TUBE GASKET

    1. A259134C05

      *a

      Protective Tape

      Remove the 4 spark plug tube gaskets with a screwdriver.

      Note:

      Be careful not to damage the cylinder head cover sub-assembly.

      Tip:

      Tape the screwdriver tip before use.

  16. REMOVE ENGINE MOUNTING BRACKET RH

    A311105

    1. Remove the 4 bolts and engine mounting bracket RH.

  17. REMOVE ENGINE MOUNTING BRACKET RH STUD BOLT

    Note:

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

  18. REMOVE TIMING CHAIN COVER ASSEMBLY

    Click here

  19. REMOVE TIMING CHAIN COVER OIL SEAL

    1. A210537C13

      *a

      Protective Tape

      *b

      Wooden Block

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

      Note:

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

      Tip:

      Tape the screwdriver tip before use.

  20. REMOVE TIMING CHAIN COVER TIGHT PLUG

    1. A196859

      Using a 14 mm hexagon wrench, remove the timing chain cover tight plug and gasket.

  21. REMOVE TIMING CHAIN COVER PLATE

    1. A259741

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

  22. SET NO. 1 CYLINDER TO TDC/COMPRESSION

    1. Temporarily install the crankshaft pulley bolt.

      A259136C13

      *1

      Crankshaft Pulley Key

      -

      -

      *a

      Approximately 7°

      *b

      Approximately 32°

      *c

      Timing Mark

      -

      -
      Tip:

      "A" in the illustration is not a timing mark.

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

      Tip:

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

    3. Remove the crankshaft pulley bolt.

  23. REMOVE TIMING CHAIN GUIDE

    1. A259137

      Remove the bolt and timing chain guide.

  24. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY

    1. A285344C03

      *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. A285345C03

      *a

      Pin

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

    3. A196877

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

  25. REMOVE CHAIN TENSIONER SLIPPER

    1. A259138

      Remove the bolt and chain tensioner slipper.

  26. REMOVE CHAIN SUB-ASSEMBLY

  27. REMOVE NO. 1 CHAIN VIBRATION DAMPER

    1. A259139

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

  28. REMOVE CRANKSHAFT TIMING SPROCKET

    1. A196881

      Remove the crankshaft timing sprocket from the crankshaft.

  29. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY

    1. A259140C06

      *a

      Hold

      *b

      Turn

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

      Note:

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

      • Do not disassemble the camshaft timing gear assembly.

  30. REMOVE CAMSHAFT TIMING SPROCKET

    1. A259141C02

      *a

      Hold

      *b

      Turn

      Hold the hexagonal portion of the No. 2 camshaft with a wrench and remove the bolt and camshaft timing sprocket.

      Note:

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

  31. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY

    1. A259142N01

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

    2. A259148

      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.

      Tip:

      Tape the screwdriver tip before use.

  32. REMOVE CAMSHAFT BEARING CAP

    1. A259149N01

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

    2. Remove the 5 camshaft bearing caps.

      Tip:

      Arrange the removed parts in the correct order.

  33. REMOVE OIL CONTROL VALVE FILTER

    1. A285348

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

  34. REMOVE CAMSHAFT

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

  35. REMOVE NO. 2 CAMSHAFT

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

  36. REMOVE NO. 1 CAMSHAFT BEARING

    1. A285349

      Remove the No. 1 camshaft bearing.

  37. REMOVE NO. 2 CAMSHAFT BEARING

    1. A285350

      Remove the No. 2 camshaft bearing.

  38. REMOVE CAMSHAFT BEARING CAP SETTING RING PIN

    Note:

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

  39. REMOVE CAMSHAFT HOUSING STUD BOLT

    Note:

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

  40. REMOVE CAMSHAFT HOUSING STRAIGHT PIN

    Note:

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

  41. 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.

      Tip:

      Arrange the removed parts in the correct order.

  42. REMOVE VALVE LASH ADJUSTER ASSEMBLY

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

      Tip:

      Arrange the removed parts in the correct order.

  43. REMOVE VALVE STEM CAP

    1. Remove the 16 valve stem caps from the cylinder head sub-assembly.

      Tip:

      Arrange the removed parts in the correct order.

  44. REMOVE CYLINDER HEAD SUB-ASSEMBLY

    Click here

  45. REMOVE CYLINDER HEAD GASKET

    Click here

  46. REMOVE CYLINDER BLOCK WATER JACKET SPACER

    1. A196938

      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.

  47. REMOVE OIL FILTER ELEMENT

    Click here

  48. REMOVE OIL PAN SUB-ASSEMBLY

    1. A311156

      Remove the 11 bolts and 2 nuts.

    2. A118769

      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 surfaces of the stiffening crankcase assembly and oil pan sub-assembly.

      • Be careful not to damage the stiffening crankcase flange.

  49. REMOVE OIL STRAINER SUB-ASSEMBLY

    1. A327296

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

  50. REMOVE NO. 1 OIL PAN BAFFLE PLATE

    1. A327297

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

  51. INSPECT CRANKSHAFT BACKLASH

    1. A196931

      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.

  52. REMOVE ENGINE BALANCER ASSEMBLY

    1. A327298

      Remove the 7 bolts and engine balancer assembly.

      Note:

      Do not disassemble the engine balancer assembly.

  53. INSPECT BALANCE SHAFT THRUST CLEARANCE

    Click here

  54. REMOVE STIFFENING CRANKCASE ASSEMBLY

    1. A196933

      Remove the 7 bolts.

    2. A196934C06

      *a

      LH Side

      *b

      RH Side

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

      Note:

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

      Tip:

      Tape the screwdriver tip before use.

  55. REMOVE CYLINDER BLOCK STUD BOLT

    Note:

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

  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. A196937

      Remove the rear engine oil seal from the cylinder block.