Engine Unit - Disassembly

1. Remove no. 1 engine hanger

2. Remove no. 2 engine hanger

3. Remove oil level gauge guide

4. Remove cylinder block water drain cock sub-assembly

5. Remove vvt sensor

6. Remove crankshaft position sensor

7. Remove oil control valve filter

8. Remove cylinder head cover sub-assembly

9. Remove cylinder head cover sub-assembly lh

10. Remove crankshaft pulley

11. Remove oil pan drain plug

12. Remove no. 2 oil pan sub-assembly

13. Remove oil strainer sub-assembly

14. Remove oil pan sub-assembly

15. Remove water pump assembly

16. Remove timing chain or belt cover sub-assembly

17. Remove timing gear case or timing chain case oil seal

18. Remove no. 1 chain tensioner assembly

19. Remove chain tensioner slipper

20. Remove no. 1 idle gear shaft

21. Remove no. 2 chain vibration damper

22. Remove chain sub-assembly

23. Remove crankshaft timing gear or sprocket

24. Remove no. 1 chain vibration damper

25. Remove camshaft timing gears and no. 2 chain (for bank 1)

26. Remove no. 2 chain tensioner assembly

27. Remove camshaft timing gears and no. 2 chain (for bank 2)

28. Remove no. 3 chain tensioner assembly

29. Remove camshafts

30. Remove no. 1 camshaft bearing

31. Remove no. 2 camshaft bearing

32. Remove cylinder heads

33. Remove no. 1 water outlet pipe

34. Remove knock sensor

35. Remove engine rear oil seal retainer

36. Remove engine rear oil seal

37. Remove valve lifter

38. Remove valve

39. Remove valve spring seat

40. Remove valve stem oil o seal or ring

41. Inspect connecting rod thrust clearance

42. Inspect connecting rod oil clearance

43. Remove piston sub-assembly with connecting rod

44. Remove connecting rod bearing

45. Remove piston ring set

46. Remove piston pin hole snap ring

47. Remove with pin piston sub-assembly

48. Inspect crankshaft thrust clearance

49. Remove crankshaft

50. Remove crankshaft thrust washer set

51. Remove crankshaft bearing

52. Remove no. 1 oil nozzle sub-assembly

​

HINT:

1. Thoroughly clean all parts to be assembled.
   
2. Before installing the parts, apply new engine oil to all sliding and rotating surfaces.
   
3. Replace all gaskets, O-rings and oil seals with new ones.
   

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

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

1. Remove the bolt and pull out the oil level gauge guide.

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

1. Remove the 2 water drain cocks.

1. Remove the 2 bolts and 2 VVT sensors.

1. Remove the bolt and crankshaft position sensor.

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

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

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

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

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

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

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

   SST

   09213-54015 (91651-60855)
   09330-00021
   

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

   SST

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

1. Remove the drain plug and gasket.

1. Remove the 10 bolts and 2 nuts.

2. Insert the blade of SST between the oil pan and No. 2 oil pan, and cut off applied sealer and remove the No. 2 oil pan.

   SST

   09032-00100
   

   NOTICE:

   1. Be careful not to damage the contact surfaces of the oil pan and No. 2 oil pan.
      
   2. Be careful not to damage the No. 2 oil pan flange.
      

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

1. Remove the 17 bolts and 2 nuts.

2. Remove the 4 stud bolts.

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

   NOTICE:

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

4. Remove the O-ring from the oil pump.

1. Remove the 17 bolts, water pump and gasket.

1. Remove the 15 bolts and 2 nuts.

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

   NOTICE:

   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.

1. Using a screwdriver, pry out the oil seal.

   NOTICE:

   Be careful not to damage the oil pump assembly. Wrap the tip of the screwdriver with tape.

NOTICE:

1. Never rotate the crankshaft with the chain tensioner removed.
   
2. When rotating the camshaft with the timing chain removed, rotate the crankshaft counterclockwise 40° from the TDC first.
   

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

2. While turning the stopper plate of the tensioner counterclockwise, insert a bar of φ3.5 mm (0.138 in.) into the holes on the stopper plate and tensioner to fix the stopper plate.

3. Remove the 2 bolts and chain tensioner.

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

1. Remove the 2 No. 2 chain vibration dampers.

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

1. While raising the No. 2 chain tensioner, insert a pin of φ1.0 mm (0.039 in.) into the hole to fix it.

2. 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.

   NOTICE:

   1. Be careful not to damage the cylinder head and valve lifter with the wrench.
      
   2. Do not disassemble the camshaft timing gear assembly.
      

1. Remove the bolt and No. 2 chain tensioner.

1. While pushing down the No. 3 chain tensioner, insert a pin of φ1.0 mm (0.039 in.) into the hole to fix it.

2. 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.

   NOTICE:

   1. Be careful not to damage the cylinder head and valve lifter with the wrench.
      
   2. Do not disassemble the camshaft timing gear assembly.
      

1. Remove the bolt and No. 3 chain tensioner.

NOTICE:

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 receives 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. Remove the camshafts of the RH bank.
   

   1. Rotate the camshafts counterclockwise using a wrench so that the cam lobes of No. 1 cylinder face each direction as shown in the illustration.

   3. Using several steps, loosen and remove the 16 bearing cap bolts uniformly in the sequence as shown in the illustration.

   4. Remove the 8 bearing caps and 2 camshafts.

2. Remove the camshafts of the LH bank.
   

   1. Using several steps, loosen and remove the 16 bearing cap bolts uniformly in the sequence as shown in the illustration.

   2. Remove the 8 bearing caps and 2 camshafts.

1. Using several steps, remove the 2 cylinder head bolts on the LH cylinder head in the sequence as shown in the illustration.

2. Using several steps, loosen the 8 cylinder head bolts on each cylinder head with a 10 mm bi-hexagon wrench in the sequence as shown in the illustration. Remove the 16 cylinder head bolts and plate washers.

   NOTICE:

   1. Be careful not to drop the plate washers into the cylinder head.
      
   2. Cylinder head warpage or cracking could result from removing bolts in incorrect order.
      

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

   NOTICE:

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

   HINT:

   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.

1. Separate the knock sensor wire.

2. Remove the 3 bolts and water outlet pipe.

1. Disconnect the knock sensor connectors.

2. Remove the 2 bolts and 2 knock sensors.

1. Remove the 5 bolts and 2 nuts.

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

1. Using a screwdriver and hammer, tap out the oil seal.

HINT:

Arrange the valve lifter in the correct order.

HINT:

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

1. Place the cylinder head on a 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, valve spring and valve spring retainer.

1. Using compressed air and a magnetic finger, remove the valve spring seat by blowing air.

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

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

   Standard thrust clearance:

   0.15 to 0.30 mm (0.0059 to 0.0118 in.)
   

   Maximum thrust clearance:

   0.35 mm (0.0138 in.)
   

1. Check the matchmarks on the connecting rod and cap are aligned to ensure correct reassembling.

2. Remove the 2 connecting rod cap bolts.

3. Clean the crank pin, bearing and connecting rod.

4. Check the crank pin and bearing for pits and scratches.

5. Lay a strip of Plastigage across the crank pin.

6. Check that the protrusion of the connecting rod cap is facing the correct direction.

7. Apply a light coat of engine oil to the threads of the connecting rod cap bolts.

8. Tighten the bolts alternately with the specified torque.

   Torque:

   25 N*m{250 kgf*cm, 18 ft.*lbf}

9. Mark the front side of each connecting cap bolt with paint.

10. Retighten the cap bolts 90° as shown in the illustration.

    NOTICE:

    Do not turn the crankshaft.

11. Remove the 2 bolts, connecting rod cap and lower bearing.

12. Measure the Plastigage at its widest point.

    Standard oil clearance:

    0.026 to 0.046 mm (0.0010 to 0.0018 in.)
    

    Maximum oil clearance:

    0.066 mm (0.0025 in.)
    

    NOTICE:

    Completely remove the Plastigage.

13. If replacing a bearing, replace it with one that has the same number marked on the connecting rod. There are 4 sizes of standard bearings, marked "1 ", "2", "3" and "4" accordingly.

    HINT:

    Standard bearing center wall thickness

    Mark	mm (in.)
    "1"	1.484 to 1.487 (0.0584 to 0.0585)
    "2"	1.487 to 1.490 (0.0585 to 0.0587)
    "3"	1.490 to 1.493 (0.0587 to 0.0588)
    "4"	1.493 to 1.496 (0.0588 to 0.0589)

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

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

   HINT:

   1. Keep the bearings, connecting rod and cap together.
      
   2. Arrange the piston and connecting rod assemblies in the correct order.
      

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

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

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

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

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

   HINT:

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

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

   Standard thrust clearance:

   0.04 to 0.24 mm (0.0016 to 0.0094 in.)
   

   Maximum thrust clearance:

   0.30 mm (0.0118 in.)
   

   If the thrust clearance is greater than the maximum, replace the pair of the thrust washers or a crankshaft.
   

   HINT:

   Thrust washer thickness is 1.93 to 1.98 mm (0.0760 to 0.0780 in.)

1. Using several steps, loosen and remove the 8 main bearing cap bolts and seal washers uniformly in the sequence as shown in the illustration.

2. Using several steps, loosen and remove the 16 main bearing cap bolts uniformly in the sequence as shown in the illustration.

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

   NOTICE:

   1. Pull up the main bearing cap while turning it little by little to the right and the left.
      
   2. Be careful not to damage the joint surfaces of the cylinder block and the main bearing cap.
      

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