БЛОК ДВИГАТЕЛЯ РАЗБОРКА


  1. REMOVE OIL FILLER CAP


    1. Remove the oil filler cap from the head cover.

  2. REMOVE VENTILATION VALVE


    1. A01E2E0E01

      Remove the ventilation valve from the head cover.

  3. REMOVE CYLINDER HEAD COVER


    1. A01DYAEE05

      Remove the 19 bolts, 2 nuts, cover and 2 gaskets.

  4. REMOVE CRANKSHAFT PULLEY

    A01DZH5E04

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

    2. Check that the timing marks of the camshaft timing gear and sprocket are aligned with the timing marks of the No. 1 bearing cap, as shown in the illustration.

    3. A01DZP7E01

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

      SST
      09213-54015   ( 91651-60855 )
      09330-00021
    4. A01E12PE01

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

      SST
      09950-50013   ( 09951-05010, 09952-05010, 09953-05010, 09954-05021 )

  5. REMOVE NO. 2 OIL PAN


    1. A01DVBSE07

      Remove the drain plug and gasket.

    2. Remove the 20 bolts and 2 nuts.

    3. Insert the blade of oil pan seal cutter between the oil pans. Cut through the applied sealer and remove the oil pan.

      Note

      Be careful not to damage the contact surfaces of the oil pans.

  6. REMOVE OIL STRAINER


    1. Remove the bolt, 2 nuts, oil strainer and gasket.

  7. REMOVE NO. 1 OIL PAN


    1. A01DYNIE02

      Remove the 16 bolts and 2 nuts.

    2. Remove the oil pan by prying between the oil pan and cylinder block with a screwdriver.

      Tech Tips

      Tape the screwdriver tip before use.

      Note

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

    3. Remove the O-ring.

  8. REMOVE TIMING CHAIN COVER


    1. A01DY5UE01

      Remove the 19 bolts and 2 nuts shown in the illustration.

    2. A01DYUJE02

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

      Tech Tips

      Tape the screwdriver tip before use.

      Note

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

    3. Remove the 3 O-rings.

    4. A01DZ60E02

      Using a 10 mm socket hexagon wrench, remove the timing gear case plug.

  9. REMOVE WATER PUMP


    1. A01DXPJE03

      Remove the 8 bolts, water pump and gasket.

  10. REMOVE TIMING CHAIN COVER OIL SEAL


    1. A01E2RCE01

      Поместите крышку цепного привода газораспределительного механизма на деревянные бруски.

    2. Обернув конец отвертки изолентой, снимите сальник.

    3. A01DWCHE01

      При помощи SST и молотка запрессуйте новый сальник так, чтобы его поверхность была заподлицо с краем крышки цепного привода газораспределительного механизма.

      SST
      09223-75010
      09950-70010   ( 09951-07150 )

      Note


      • Не допускайте попадания на кромку посторонних материалов.

      • Не стучите по сальнику, направляя удары под углом.

      Tech Tips

      При установке шкива коленчатого вала проверьте форму шкива. Пригодный шкив имеет канавку (см. стр. Click here).

    4. Нанесите тонкий слой универсальной консистентной смазки на кромку нового сальника.

  11. REMOVE OIL PUMP RELIEF VALVE


    1. A01DX68E04

      Using a 27 mm socket wrench, remove the plug and gasket.

    2. Remove the valve spring and relief valve.

  12. REMOVE TIMING CHAIN GUIDE


    1. A01E2T7E02

      Remove the 2 bolts, timing chain guide and O-ring.

  13. REMOVE NO. 1 TIMING CHAIN TENSIONER

    A01E1XKE02

    Note


    • When the chain tensioner is removed, do not rotate the crankshaft.

    • When the chain is removed and the camshaft needs to be rotated, rotate the crankshaft 90° to the right.


    1. Move the stopper plate upward to release the lock, and push the plunger deep into the tensioner.

    2. Move the stopper plate downward to set the lock, and insert a hexagon wrench into the stopper plate's hole.

    3. A01DX7EE01

      Remove the bolt, nut, chain tensioner and gasket.

  14. REMOVE CHAIN TENSIONER SLIPPER


    1. A01DWVRE01

      Remove the bolt and tensioner slipper.

  15. REMOVE NO. 1 VIBRATION DAMPER


    1. A01DV3DE01

      Remove the bolt, nut and vibration damper.

  16. REMOVE TIMING CHAIN

  17. REMOVE CRANKSHAFT TIMING SPROCKET


    1. A01DVM2E01

      Remove the crankshaft timing sprocket from the crankshaft.

  18. REMOVE CRANKSHAFT POSITION SENSOR PLATE

  19. REMOVE CAMSHAFT


    1. A01DVFME01

      Uniformly loosen the 21 bearing cap bolts in the several passes in the order shown in the illustration.

    2. Remove the 9 bearing caps, oil delivery pipe, O-ring and 2 camshafts.

      Note


      • Place the camshaft on a flat surface, maintain this position and loosen the bolts uniformly.

      • Do not pry the camshaft with a tool by applying excessive force to it.

      • Do not damage the reception part of the exhaust on the cylinder head side.

    3. A01DYPFE04

      Remove the oil delivery pipe and O-ring from the bearing caps.

    4. A01DYQ1E01

      Remove the 9 bearing caps.

    5. Remove the 2 camshafts.

  20. REMOVE CAMSHAFT TIMING SPROCKET


    1. A01DXT3E01

      Fix the camshaft with a vise, and then remove the sprocket bolt and camshaft timing sprocket.

      Note

      Be careful not to damage the camshaft.

  21. REMOVE CAMSHAFT TIMING GEAR


    1. A01E0TYE01

      Remove the flange bolt of the camshaft timing gear.

      Note


      • Be sure not to remove the other 3 bolts.

      • If planning to reuse the gear, be sure to release the straight pin lock before installing the gear.

  22. REMOVE CYLINDER HEAD


    1. A01DZZBE01

      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.

      Note


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

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

    2. Remove the cylinder head and gasket.

  23. REMOVE NO. 2 CHAIN VIBRATION DAMPER


    1. A01DXTCE01

      Move the stopper plate downward to release the lock, and push the plunger deep into the tensioner.

    2. Move the stopper plate upward to set the lock, and insert a hexagon wrench into the stopper plate's hole.

    3. A01E08XE01

      Remove the bolt and chain vibration damper.

  24. REMOVE NO. 3 CHAIN VIBRATION DAMPER


    1. A01DXTXE01

      Remove the 2 bolts and chain vibration damper.

  25. REMOVE NO. 2 CHAIN TENSIONER


    1. A01E1DFE01

      Remove the hexagon wrench from the tensioner.

    2. Remove the nut and chain tensioner.

  26. REMOVE NO. 2 CHAIN


    1. A01DVELE01

      Remove the bolt, balance shaft drive gear shaft and balance shaft drive gear.

    2. Remove the No. 2 crankshaft timing sprocket and chain.

  27. REMOVE NO. 4 CHAIN VIBRATION DAMPER


    1. A01E2KEE01

      Remove the 2 bolts and No. 4 vibration damper.

  28. REMOVE CRANKSHAFT PULLEY SET KEY


    1. A01DYTTE01

      Remove the 2 pulley set keys from the crankshaft.

  29. REMOVE OIL FILTER


    1. A01DZ2HE01

      Using SST, remove the oil filter.

      SST
      09228-07501

  30. REMOVE OIL FILTER UNION


    1. A01E02UE03

      Using a 27 mm socket wrench, remove the oil filter union.

  31. REMOVE OIL FILTER BRACKET


    1. A01DZA3E03

      Remove the 2 screw plugs and 2 gaskets from the oil filter bracket.

    2. Remove the 2 bolts, nut and oil filter bracket.

    3. A01DW3SE04

      Remove the gasket and O-ring.

    4. A01DWGKE01

      Using a 14 mm hexagon wrench, remove the oil filter bracket union.

  32. REMOVE ENGINE REAR OIL SEAL RETAINER


    1. A01DWM5E01

      Remove the 6 bolts.

    2. Using a screwdriver with its tip taped, pry out the oil seal retainer.

  33. REMOVE VALVE ROCKER ARM

    Tech Tips

    Each rocker arm must be reinstalled to its original location.

  34. REMOVE VALVE STEM CAP

    Tech Tips

    Each valve stem cap must be reinstalled to its original location.

  35. REMOVE VALVE LASH ADJUSTER

    Tech Tips

    Each lash adjuster must be reinstalled to its original location.

  36. REMOVE INTAKE VALVE


    1. A01DVB3E01

      Using SST and wooden blocks, compress the compression spring and remove the valve retainer locks.

      SST
      09202-70020   ( 09202-00010 )
    2. A01E229E01

      Remove the retainer, compression spring, valve, valve spring and spring seat.

      Tech Tips

      Each intake valve must be reinstalled to its original location.

  37. REMOVE EXHAUST VALVE


    1. A01E1ONE01

      Using SST and wooden blocks, compress the compression spring and remove the valve retainer locks.

      SST
      09202-70020   ( 09202-00010 )
    2. A01DWCJ

      Remove the retainer, compression spring, valve, valve spring and spring seat.

      Tech Tips

      Each exhaust valve must be reinstalled to its original location.

  38. REMOVE VALVE STEM OIL SEAL


    1. A01E0D7E01

      Using needle-nose pliers, remove the oil seal.

  39. REMOVE OIL CONTROL VALVE FILTER


    1. A01E1ZWE01

      Using an 8 mm hexagon wrench, remove the screw plug.

    2. Remove the oil control valve filter and gasket.

  40. REMOVE NO. 1 STRAIGHT SCREW PLUG


    1. A01DX2UE01

      Using a 10 mm hexagon wrench, remove the 3 screw plugs.

  41. REMOVE NO. 2 STRAIGHT SCREW PLUG


    1. A01DWLHE01

      Using a 9 mm hexagon wrench, remove the screw plug.

  42. INSPECT CONNECTING ROD THRUST CLEARANCE


    1. A01E0MDE01

      Using a dial indicator, measure the thrust clearance while moving the connecting rod back and forth.

      Standard thrust clearance
      0.15 to 0.35 mm (0.006 to 0.014 in.)
      Maximum thrust clearance
      0.40 mm (0.016 in.)

      If the thrust clearance is greater than the maximum, replace the connecting rod assembly(s). If necessary, replace the crankshaft.

  43. INSPECT CONNECTING ROD OIL CLEARANCE


    1. A01DYGAE01

      Check that the front mark on the connecting rod and cap are aligned to ensure the correct reassembly.

      Tech Tips

      The front mark on the connecting rods and caps are for ensuring the correct reassembly.

    2. A01DZQ1E01

      Remove the 2 connecting rod cap bolts.

    3. Using the 2 removed connecting rod cap bolts, remove the connecting rod cap and lower bearing by wiggling the connecting rod cap right and left.

      Tech Tips

      Keep the lower bearing inserted to the connecting rod cap.

    4. Clean the crank pin and bearing.

    5. Check the crank pin and bearing for pitting and scratches.

    6. A01E33WE02

      Lay a strip of Plastigage on the crank pin.

    7. Install the connecting rod cap.

      Note

      Do not turn the crankshaft.


      1. Match the numbered connecting rod cap with the connecting rod.

      2. Align the pins of the connecting rod cap with the pin holes of the connecting rod, and install the connecting rod cap.

      3. A01DW8TE01

        Check that the front mark of the connecting rod cap is facing forward.

    8. Install the connecting rod cap bolts.

      Tech Tips


      • The connecting rod cap bolts are tightened in 2 progressive steps.

      • If any connecting rod bolt is broken or deformed, replace it.


      1. Apply a light coat of engine oil on the threads and under the heads of the connecting rod cap bolts.

      2. Install and alternately tighten the bolts of the connecting rod cap in several passes.

        Torque:
        24.5 N*m  { 250 kgf*cm, 18 ft.*lbf }

        If any one of the connecting rod cap bolts does not meet the torque specification, replace the cap bolts.

      3. A01DXZJE01

        Mark the front of the connecting rod cap bolts with paint.

      4. Retighten the connecting rod cap bolts 90° as shown.

      5. Check that the painted mark is now at a 90° angle to the front.

    9. Remove the 2 bolts and connecting rod cap.

    10. A01DZ3JE01

      Measure the Plastigage at its widest point.

      Standard oil clearance
      0.039 to 0.066 mm (0.0015 to 0.0026 in.)

      If the crank pin or bearing is damaged, replace the bearings. If necessary, replace the crankshaft.

      Tech Tips

      If replacing a bearing, replace it with one that has the same number as its respective connecting rod cap. Each bearing's standard thickness is indicated by a 4, 5 or 6 mark on its surface.

      Standard bearing center wall thickness
      Mark Specified Condition
      4 1.484 to 1.487 mm (0.0584 to 0.0585 in.)
      5 1.488 to 1.490 mm (0.0586 to 0.0587 in.)
      6 1.491 to 1.493 mm (0.0587 to 0.0588 in.)

    11. Completely remove the Plastigage.

  44. REMOVE PISTON WITH CONNECTING ROD


    1. A01E23TE03

      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 bearing, connecting rod and cap together.

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

  45. INSPECT CRANKSHAFT THRUST CLEARANCE


    1. A01DXHSE01

      Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver.

      Standard thrust clearance
      0.020 to 0.220 mm (0.0008 to 0.0087 in.)
      Maximum thrust clearance
      0.30 mm (0.0118 in.)

      If the thrust clearance is greater than the maximum, replace the thrust washers as a set.

      Thrust washer thickness
      2.440 to 2.490 mm (0.0961 to 0.0980 in.)

  46. INSPECT CRANKSHAFT OIL CLEARANCE


    1. A01DX53E03

      Uniformly loosen the 10 bearing cap bolts in several passes in the sequence shown in the illustration.

      Tech Tips


      • Keep the lower bearings and crankshaft bearing caps together.

      • Arrange the thrust washers in the correct order.

    2. Clean each main journal and bearing.

    3. Check each main journal and bearing for pitting and scratches.

      If the journal or bearing is damaged, replace the bearings. If necessary, grind or replace the crankshaft.

    4. Place the crankshaft on the cylinder block.

    5. A01DV4AE01

      Lay a strip of Plastigage across each journal.

    6. A01DW7VE01

      Install the 5 crankshaft bearing caps in their proper locations.

      Note

      Do not turn the crankshaft.

    7. A01DX53E01

      Install the crankshaft bearing cap bolts.

      Tech Tips


      • The main bearing cap bolts are tightened in 2 progressive steps.

      • If any of the main bearing cap bolts are broken or deformed, replace as necessary.


      1. Install and uniformly tighten the 10 main bearing cap bolts in the sequence shown in the illustration.

        Torque:
        39 N*m  { 398 kgf*cm, 29 ft.*lbf }

        If any one of the main bearing cap bolts does not meet the torque specification, replace the main bearing cap bolt.

      2. A01DXZJE01

        Mark the front of the bearing cap bolts with paint.

      3. Retighten the bearing cap bolts by 90° in the numerical order above.

      4. Check that the painted mark is now at a 90° angle to the front.

    8. Remove the 10 bolts and 5 crankshaft bearing caps.

    9. A01DWO1E04

      Measure the Plastigage at its widest point.

      Standard oil clearance
      Item Specified Condition
      No. 3 journal 0.030 to 0.055 mm (0.0012 to 0.0022 in.)
      Other journal 0.024 to 0.049 mm (0.0009 to 0.0019 in.)
      Maximum oil clearance
      0.10 mm (0.0039 in.)

      If the oil clearance is greater than the maximum, replace the crankshaft bearings. If necessary, replace the crankshaft.

      Tech Tips

      If replacing the cylinder block, the bearing standard clearance will be 0.030 to 0.055 mm (0.0012 to 0.0022 in.).

      Tech Tips

      If replacing a bearing, first check the number on the cylinder block for the bearing's respective journal. Then replace the bearing with one that has the same number. Each bearing's standard thickness is indicated by a 1, 2 or 3 mark on its surface.

      Cylinder block main journal bore diameter (Reference):
      Mark Specified Condition
      1 64.004 to 64.010 mm (2.5198 to 2.5201 in.)
      2 64.011 to 64.016 mm (2.5201 to 2.5203 in.)
      3 64.017 to 64.022 mm (2.5203 to 2.5206 in.)
      Standard bearing center wall thickness (Reference)
      Mark Specified Condition
      1 1.987 to 1.990 mm (0.0782 to 0.0783 in.)
      2 1.990 to 1.993 mm (0.0783 to 0.0785 in.)
      3 1.993 to 1.996 mm (0.0785 to 0.0786 in.)

    10. Completely remove the Plastigage.

  47. REMOVE CRANKSHAFT


    1. Lift out the crankshaft.

      Tech Tips

      Keep the upper crankshaft bearings and upper thrust washers together with the cylinder block.

  48. REMOVE PISTON WITH PIN


    1. A01DXHVE02

      Check fit between the piston and piston pin.


      1. Try to move the piston back and forth on the piston pin.

        If any movement is felt, replace the piston and pin as a set.

    2. A01E0ORE01

      Remove the piston rings.


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

      2. Remove the rail and expander by hand.

        Tech Tips

        Arrange the piston rings in the correct order only.

    3. A01DV4GE01

      Disconnect the connecting rod from the piston.


      1. Using a small screwdriver, pry off the snap ring from the piston.

      2. A01DUZRE02

        Gradually heat the piston to approximately 80 to 90°C (176 to 194°F).

      3. A01E1SXE01

        Using a brass bar and plastic-faced hammer, 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.

  49. REMOVE CYLINDER BLOCK WATER DRAIN COCK

  50. REMOVE OIL NOZZLE


    1. Using a 5 mm hexagon wrench, remove the oil nozzle.

  51. INSPECT BALANCE SHAFT THRUST CLEARANCE


    1. A01E14SE01

      Using a dial indicator, measure the thrust clearance while moving the balance shaft back and forth.

      Standard thrust clearance
      0.07 to 0.13 mm (0.0027 to 0.0051 in.)
      Maximum thrust clearance
      0.20 mm (0.0079 in)

      If the thrust clearance is greater than the maximum, replace the balance shaft thrust washer. If necessary, replace the balance shaft.

  52. REMOVE NO. 1 BALANCE SHAFT


    1. A01E1Z7E01

      Remove the bolt.

    2. A01DW17E01

      Remove the balance shaft from the cylinder block.

      Note

      When removing the balance shaft, make sure to support the balance shaft with both hands and avoid scratching the balance shaft bearing on the cylinder block side.

  53. REMOVE NO. 1 BALANCE SHAFT DRIVEN GEAR


    1. A01DX0RE01

      Mount the head portion of the balance shaft in a vise.

      Note

      Be careful not to damage the balance shaft.

    2. Remove the bolt.

    3. Remove the No. 1 balance shaft driven gear (A), sliding key (B), No. 1 balance shaft thrust washer (C) and balance shaft thrust spacer (D).

  54. REMOVE NO. 2 BALANCE SHAFT


    1. A01DY00E01

      Remove the 2 bolts.

    2. A01DV9PE01

      Remove the balance shaft from the cylinder block.

      Note

      When removing the balance shaft, make sure to support the balance shaft with both hands and avoid scratching the balance shaft bearing on the cylinder block side.

  55. REMOVE NO. 2 BALANCE SHAFT DRIVEN GEAR


    1. A01DWBGE01

      Mount the head portion of the balance shaft in a vise.

      Note

      Be careful not to damage the balance shaft.

    2. Remove the bolt.

    3. Remove the No. 2 balance shaft driven gear (A) and No. 2 balance shaft thrust washer (B).