Disassembly

ENGINE UNIT

COMPONENTS (Part 1):

COMPONENTS (Part 2):

COMPONENTS (Part 3):

COMPONENTS (Part 4):

COMPONENTS (Part 5):

DISASSEMBLY

1. REMOVE OIL FILLER CAP SUB-ASSEMBLY
(a) Remove the oil filler cap.

2. REMOVE OIL FILLER CAP GASKET
(a) Remove the oil filler cap gasket.

3. REMOVE VENTILATION VALVE SUB-ASSEMBLY
(a) Remove the ventilation valve.

4. REMOVE SPARK PLUG
(a) Remove the spark plugs.

5. REMOVE OIL FILTER SUB-ASSEMBLY
(a) Using SST, remove the oil filter.
SST 09228-06501

HINT: Place a container for oil to be drained before removing the oil filter.

6. REMOVE OIL FILTER UNION
(a) Using a 12 mm hexagon wrench, remove the union.

7. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY
(a) Remove the 8 bolts, 2 nuts and cylinder head cover.

8. REMOVE CYLINDER HEAD COVER GASKET
(a) Remove the cylinder head cover gasket.
9. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY

10. REMOVE CRANKSHAFT POSITION SENSOR
(a) Remove the wire harness clamp.
(b) Separate the wire harness from the wire harness clamp bracket.

11. REMOVE CAMSHAFT POSITION SENSOR
(a) Remove the bolt and sensor.
12. SET NO. 1 CYLINDER TO TDC / COMPRESSION
13. REMOVE CRANKSHAFT PULLEY

14. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY
(a) Remove the bolt and camshaft timing oil control valve assembly.
15. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY

16. REMOVE WATER PUMP PULLEY
(a) Using SST, remove the water pump pulley.
SST 09960-10010 (09962-01000, 09963-00700)

17. REMOVE WATER PUMP ASSEMBLY
(a) Remove the 4 bolts, 2 nuts, bracket and water pump.

18. REMOVE OIL PAN DRAIN PLUG
(a) Remove the oil pan drain plug and gasket.
19. REMOVE OIL PAN SUB-ASSEMBLY
20. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY

21. REMOVE TIMING CHAIN CASE OIL SEAL
(a) Using a screwdriver and hammer, remove the oil seal.
22. REMOVE NO. 1 CRANKSHAFT POSITION SENSOR PLATE
23. REMOVE CHAIN TENSIONER SLIPPER
24. REMOVE NO. 1 CHAIN VIBRATION DAMPER
25. REMOVE TIMING CHAIN GUIDE
26. REMOVE CHAIN SUB-ASSEMBLY
27. REMOVE CRANKSHAFT TIMING SPROCKET
28. REMOVE NO. 2 CHAIN SUB-ASSEMBLY

29. REMOVE KEYS
(a) Remove the 2 pulley set keys from the crankshaft.

30. REMOVE NO. 2 CAMSHAFT
(a) Uniformly loosen and remove the camshaft's 10 bearing cap bolts in the sequence shown in the illustration. Then remove the 5 bearings.
(b) Remove the No. 2 camshaft.

31. REMOVE CAMSHAFT
(a) Uniformly loosen and remove the camshaft's 10 bearing cap bolts in the sequence shown in the illustration. Then remove the 5 bearings.
(b) Remove the camshaft.

32. REMOVE NO. 1 CAMSHAFT BEARING
(a) Remove the No. 1 camshaft bearing.

33. REMOVE NO. 2 CAMSHAFT BEARING
(a) Remove the No. 2 camshaft bearing.

34. REMOVE CAMSHAFT TIMING SPROCKET
(a) Fix the camshaft in a vise and remove the camshaft timing sprocket.

NOTICE: Be careful not to damage the camshaft.

35. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY

36. REMOVE CYLINDER HEAD SUB-ASSEMBLY
(a) 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.

NOTICE:
^ Be careful not to drop washers into the cylinder head.
^ Head warpage or cracking could result from removing bolts in an incorrect order.

37. REMOVE CYLINDER HEAD GASKET
(a) Remove the cylinder head gasket.

38. REMOVE CYLINDER BLOCK WATER JACKET SPACER
(a) Using needle-nose pliers, remove the cylinder block water jacket spacer.

NOTICE: Be sure to remove the water jacket spacer if the cylinder block is to be turned upside down.

39. REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY
(a) Remove the water drain cock from the stiffening crankcase.
(b) Remove the water drain cock plug from the water drain cocks.

40. REMOVE OIL CONTROL VALVE FILTER
(a) Using an 8 mm socket hexagon wrench, remove the plug and filter.

41. REMOVE NO. 1 WITH HEAD TAPER SCREW PLUG
(a) Remove the taper screw plug.

42. REMOVE OIL PUMP ASSEMBLY
(a) Remove the 3 bolts, oil pump and gasket.

43. REMOVE NO. 1 AND NO. 2 BALANCESHAFT SUB-ASSEMBLY
(a) Uniformly loosen and remove the 8 bolts in the sequence shown in the illustration.

(b) Remove the No. 1 and No. 2 balance shafts.

44. REMOVE NO. 1 BALANCESHAFT BEARING
(a) Remove the balanceshaft bearings.

45. REMOVE ENGINE REAR OIL SEAL
(a) Using a knife, cut off the oil seal lip.
(b) Using a screwdriver with its tip taped, pry out the oil seal.

NOTICE: After removing the oil seal, check the crankshaft for damage. If it is damaged, smooth the surface with 400-grit sandpaper.

46. REMOVE STIFFENING CRANKCASE ASSEMBLY
(a) Uniformly loosen and remove the 11 bolts in the sequence shown in the illustration.

(b) Using a screwdriver, remove the crankcase by prying between the crankcase and cylinder block.

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

47. REMOVE PISTON SUB-ASSEMBLY WITH CONNECTING ROD
(a) Using a ridge reamer, remove all the carbon from the top of the cylinder.

(b) Check that the matchmarks on the connecting rod and cap are aligned to ensure correct reassembly.

HINT: The matchmarks on the connecting rods and caps are provided to ensure correct reassembly.

(c) Using a 12 mm socket wrench, uniformly loosen the 2 bolts.
(d) 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.

HINT: Keep the lower bearing inserted in the connecting rod cap.

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

HINT:
^ Keep the bearing, connecting rod and cap together.
^ Arrange the piston and connecting rod assemblies in the correct order.

48. REMOVE CONNECTING ROD BEARING
(a) Remove the connecting rod bearings.

HINT: Arrange the removed parts in the correct order.

49. REMOVE PISTON RING SET
(a) Using a piston ring expander, remove the 2 compression rings.
(b) Remove the oil ring rail and oil ring expander by hand.

HINT: Arrange the removed parts in the correct order.

50. REMOVE PISTON PIN HOLE SNAP RING
(a) Using a screwdriver, pry out the 2 snap rings.

51. REMOVE PISTON
(a) Gradually heat each piston to approximately 80 to 90°C (176 to 194°F).

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

HINT:
^ The piston and pin are a matched set.
^ Arrange the pistons, pins, rings, connecting rods and bearings in the correct order.

52. REMOVE CRANKSHAFT
(a) Uniformly loosen and remove the 10 main bearing cap bolts in the sequence shown in the illustration.

(b) Use 2 removed main bearing cap bolts to remove the 5 main bearing caps and 5 lower bearings.

NOTICE: Insert the bolts into the caps in turn. Ease the cap out by gently pulling up and applying force toward the front and back sides of the cylinder block, as shown in the illustration. Take care not to damage the contact surfaces of the cap and cylinder block.

HINT:
^ Keep the lower bearing and main bearing cap together.
^ Arrange the main bearing caps in the correct order.

(c) Lift out the crankshaft.

53. REMOVE UPPER CRANKSHAFT THRUST WASHER
(a) Remove the upper crankshaft thrust washers from the cylinder block.

54. REMOVE CRANKSHAFT BEARING
(a) Remove the 5 upper main bearings from the cylinder block.

HINT: Arrange the bearings in the correct order.

55. REMOVE NO. 2 CRANKSHAFT BEARING
(a) Remove the 5 lower main bearings from the 5 main bearing caps.

HINT: Arrange the main bearings and thrust washers in the correct order.

56. REMOVE STUD BOLT

57. REMOVE NO. 1 OIL NOZZLE SUB-ASSEMBLY
(a) Using a 5 mm hexagon wrench, remove the bolts and oil nozzles.
58. CLEAN CYLINDER BLOCK

NOTICE: If the cylinder is washed at high temperatures, the cylinder liner sticks out beyond the cylinder block. Always wash the cylinder block at a temperature of 45°C (113°F) or less.