ENGINE UNIT DISASSEMBLY

PROCEDURE

  1. REMOVE ENGINE COVER JOINT

    1. A196900

      Remove the 3 engine cover joints.

  2. REMOVE SPARK PLUG

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  3. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Intake Side)

    Click here

  4. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Exhaust Side)

    Click here

  5. REMOVE CAMSHAFT POSITION SENSOR (for Intake Side)

    Click here

  6. REMOVE CAMSHAFT POSITION SENSOR (for Exhaust Side)

    Click here

  7. REMOVE OIL FILLER CAP SUB-ASSEMBLY

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

    2. Remove the gasket from the oil filler cap.

  8. REMOVE CRANKSHAFT POSITION SENSOR

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  9. REMOVE PCV VALVE

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  10. REMOVE PCV CASE

    1. A195869

      Remove the 8 bolts and 2 nuts.

    2. A195878

      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.

  11. REMOVE SEPARATOR CASE

    1. A195870

      Remove the 2 bolts, separator case and gasket.

  12. REMOVE NO. 1 WATER BY-PASS PIPE

    1. A194876

      Remove the bolt, 2 nuts, water by-pass pipe and gasket.

  13. REMOVE WATER INLET

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  14. REMOVE THERMOSTAT

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  15. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY

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  16. REMOVE ENGINE WATER PUMP ASSEMBLY

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  17. REMOVE OIL COOLER ASSEMBLY (w/ Oil Cooler)

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  18. REMOVE WATER INLET HOUSING

    1. A195872

      Remove the 4 bolts, nut, water inlet housing and gasket.

  19. REMOVE CRANKSHAFT PULLEY

    1. A297368C01

      *a

      Turn

      *b

      Hold

      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 holdingtool): 91551-80650 (quantity: 2)

    2. A195874C07

      *1

      Pulley Bolt

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

      09950-50013

      09954-05011

      09951-05010

      09952-05010

      09953-05020

      Tip:

      Apply lubricant to the threads and end of SST.

  20. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY

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  21. REMOVE SPARK PLUG TUBE GASKET

    Click here

  22. REMOVE ENGINE MOUNTING BRACKET RH

    Click here

  23. REMOVE TIMING CHAIN COVER ASSEMBLY

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  24. REMOVE TIMING CHAIN COVER TIGHT PLUG

    1. A196859

      Using a 14 mm hexagon wrench, remove the plug and gasket.

  25. REMOVE TIMING CHAIN COVER PLATE

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  26. REMOVE TIMING CHAIN COVER OIL SEAL

    Click here

  27. SET NO. 1 CYLINDER TO TDC/COMPRESSION

    Click here

  28. REMOVE TIMING CHAIN GUIDE

    Click here

  29. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY

    Click here

  30. REMOVE CHAIN TENSIONER SLIPPER

    Click here

  31. REMOVE CHAIN SUB-ASSEMBLY

  32. REMOVE NO. 1 CHAIN VIBRATION DAMPER

    Click here

  33. REMOVE CRANKSHAFT TIMING SPROCKET

    1. A196881

      Remove the crankshaft timing sprocket from the crankshaft.

  34. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY

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  35. REMOVE CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY

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  36. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY

    Click here

  37. REMOVE CAMSHAFT BEARING CAP

    Click here

  38. REMOVE OIL CONTROL VALVE FILTER

    1. A196915

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

  39. REMOVE CAMSHAFT

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  40. REMOVE NO. 1 CAMSHAFT BEARING

    1. A196916

      Remove the No. 1 camshaft bearing.

  41. REMOVE NO. 2 CAMSHAFT BEARING

    1. A196917

      Remove the No. 2 camshaft bearing.

  42. REMOVE CAMSHAFT HOUSING STUD BOLT

    Note:

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

  43. REMOVE CAMSHAFT BEARING CAP SETTING RING PIN

    Note:

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

  44. REMOVE CAMSHAFT HOUSING STRAIGHT PIN

    Note:

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

  45. REMOVE NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY

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  46. REMOVE VALVE LASH ADJUSTER ASSEMBLY

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  47. REMOVE VALVE STEM CAP

    Click here

  48. REMOVE CYLINDER HEAD SUB-ASSEMBLY

    Click here

  49. REMOVE CYLINDER HEAD GASKET

    Click here

  50. 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.

  51. REMOVE OIL FILTER ELEMENT

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  52. REMOVE OIL PAN SUB-ASSEMBLY

    1. A196918

      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.

  53. REMOVE OIL STRAINER SUB-ASSEMBLY

    1. A196919

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

  54. REMOVE NO. 1 OIL PAN BAFFLE PLATE

    1. A196920

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

  55. 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.

  56. REMOVE ENGINE BALANCER ASSEMBLY

    1. A196921

      Remove the 7 bolts and engine balancer assembly.

      Note:

      Do not disassemble the engine balancer assembly.

  57. INSPECT BALANCE SHAFT THRUST CLEARANCE

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  58. 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 by prying between the stiffening crankcase 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.

      Tip:

      Tape the screwdriver tip before use.

  59. REMOVE STIFFENING CRANKCASE STUD BOLT

    Note:

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

  60. REMOVE STIFFENING CRANKCASE RING PIN

    Note:

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

  61. REMOVE REAR ENGINE OIL SEAL

    1. A196937

      Remove the rear engine oil seal from the cylinder block.