Engine Unit - Disassembly

1. Remove spark plug

2. Remove knock sensor

3. Remove engine oil pressure switch assembly

4. Remove engine coolant temperature sensor

5. Remove water inlet

6. Remove thermostat

7. Remove oil filler cap sub-assembly

8. Remove oil filler cap gasket

9. Remove crankshaft position sensor

10. Remove ventilation valve sub-assembly

11. Remove cylinder head cover sub-assembly

12. Remove cylinder head cover gasket

13. Remove camshaft timing oil control valve assembly (for unleaded gasoline specification vehicle)

14. Remove oil level gauge guide

15. Remove water pump pulley

16. Remove crankshaft damper sub-assembly

17. Remove transverse engine engine mounting bracket

18. Remove water pump assembly

19. Remove oil pump assembly

20. Remove oil pump seal

21. Remove chain tensioner assembly no.1

22. Remove chain tensioner slipper

23. Remove chain vibration damper no. 1

24. Remove chain sub-assembly

25. Remove fuel delivery pipe sub-assembly

26. Remove delivery pipe no. 1 spacer

27. Remove injector vibration insulator

28. Remove fuel injector assembly

29. Remove camshaft position sensor

30. Remove no. 2 camshaft

31. Remove camshaft timing sprocket

32. Remove camshaft

33. Remove camshaft timing gear assembly (for unleaded gasoline specification vehicle)

34. Remove camshaft timing sprocket (for leaded gasoline specification vehicle)

35. Remove cylinder head sub-assembly

36. Remove cylinder head gasket

37. Remove oil filter sub-assembly

38. Remove oil filter union

39. Remove engine rear oil seal

40. Remove oil pan sub-assembly no. 2

41. Remove oil strainer sub-assembly

42. Remove oil pan sub-assembly

43. Remove stud bolt

44. Remove piston sub-assembly with connecting rod

45. Remove connecting rod bearing

46. Remove crankshaft

47. Remove crankshaft bearing

48. Remove crankshaft thrust washer upper

49. Remove piston ring set

50. Remove with pin piston sub-assembly

51. Remove cylinder block water drain cock sub-assembly

52. Remove stud bolt

53. Remove ring pin

54. Remove straight pin

​

1. Using a spark plug wrench, remove the 4 spark plugs.

1. Remove the nut and remove the knock sensor.

1. Using a 24 mm deep socket wrench, remove the oil pressure switch.

1. Using SST, remove the engine coolant temperature sensor.

   SST

   09817-33190
   

1. Remove the 2 nuts and remove the water inlet.

1. Remove the thermostat.

2. Remove the gasket from the thermostat.

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

1. Using a screwdriver, remove the gasket from the oil filler cap.

1. Remove the bolt and the crankshaft position sensor.

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

1. Remove the 9 bolts, 2 nuts and 2 seal washers and then remove the cylinder head cover sub-assembly.

1. Remove the gasket from the cylinder head cover.

1. Remove the bolt and the camshaft timing oil control valve.

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

1. Using SST, hold the pump pulley.

   SST

   09960-10010 (09962-01000, 09963-00700)
   

2. Remove the 3 bolts and the pump pulley.

1. Set cylinder No. 1 to TDC/compression.
   

   1. Turn the crankshaft damper sub-assembly, and align its timing notch with timing mark "0" of the oil pump.

   3. for Unleaded Gasoline Specification Vehicle:
      Check that the timing marks on the camshaft timing sprocket and the camshaft timing gear are all facing upward, as shown in the illustration.
      If not, turn the crankshaft 1 complete revolution (360°) and align the marks as above.

   5. for Leaded Gasoline Specification Vehicle:
      Check that both timing marks on the camshaft timing sprockets are facing upward as shown in the illustration.

      HINT:

      If not, turn the crankshaft 1 complete revolution (360°) and align the marks as above.

2. Using 2 SSTs, loosen the bolt while holding the crankshaft damper sub-assembly.

   SST

   09213-14010 (91651-60865)
   09330-00021
   

   NOTICE:

   Check the SST installation positions when installing them, to avoid the SST fixing bolts from coming into contact with the oil pump assembly.

3. Remove the SSTs and the bolt.

4. Remove the crankshaft damper sub-assembly.

1. Remove the 4 bolts and remove the transverse engine mounting bracket.

1. Remove the 3 bolts and 2 nuts and remove the water pump and gasket.

1. Remove the 15 bolts and nut.

2. Using a screwdriver with its tip wrapped in protective tape, prize the oil pump assembly to remove it.

   NOTICE:

   Do not damage the contact surface of the oil pump assembly and oil pan sub-assembly.

3. Remove the 2 O-rings from the cylinder block and oil pan sub-assembly.

1. Using a screwdriver with its tip wrapped in tape, remove the oil seal.

NOTICE:

1. Do not 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. Pull up the stopper plate and hold it with its lock released.

2. Unlock the plunger of the tensioner and push it in to the end.

3. Pull down the stopper plate with the plunger pushed to the end and lock the plunger.

4. Insert a 3 mm (0.12 in.) diameter bar into the hole in the stopper plate and lock the plunger.

5. Remove the 2 bolts and remove the chain tensioner assembly No. 1.

1. Remove the chain tensioner slipper.

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

1. Remove the 3 bolts and remove the fuel delivery pipe sub-assembly with 4 fuel injectors.

   NOTICE:

   Do not drop the fuel injectors when removing the fuel delivery pipe sub-assembly.

1. Remove the 2 delivery pipe No. 1 spacers.

1. Remove the 4 injector vibration insulators.

1. Pull the 4 fuel injector assemblies out of the fuel delivery pipe sub-assembly.

1. Remove the bolt and the camshaft position sensor.

NOTICE:

When rotating the camshaft with the timing chain removed, rotate the crankshaft counterclockwise 40° from the TDC first, and align the oil jet hole with the paint mark. This prevents the pistons from coming into contact with the valves.

1. Using several steps, loosen and remove the 11 bearing cap bolts uniformly in the sequence shown in the illustration, then remove camshaft bearing cap No. 1, camshaft bearing cap No. 2 and camshaft No. 2.

   NOTICE:

   Loosen each bolt uniformly while keeping the camshaft level.

1. Clamp the camshaft in a vice.

2. Remove the flange bolt and the camshaft timing sprocket.

   NOTICE:

   Do not damage the camshaft.

1. Using several steps, loosen and remove the 8 bearing cap bolts uniformly in the sequence shown in the illustration, then remove camshaft bearing cap No. 2 and the camshaft.

   NOTICE:

   Loosen each bolt uniformly keeping the camshaft level.

1. Clamp the camshaft in a vise, and confirm that it is locked.

   NOTICE:

   Do not damage the camshaft.

2. Cover the 4 oil paths of the cam journal with tape as shown in the illustration.

   HINT:

   One of the 2 grooves located on the cam journal is for retarding cam timing (upper) and the other is for advancing cam timing (lower). Each groove has 2 oil paths. Plug one of the oil paths for each groove with a piece of rubber before wrapping the cam journal with the tape.

3. Puncture the tape covering the advance oil path and the retard oil path on the opposite side from the advance oil path.

4. Apply at about 150 kPa (1.5 kgf*cm²) air pressure into the 2 broken paths (the advance side path and the retard side path).

   NOTICE:

   Cover the paths with a shop rag or piece of cloth to prevent oil splashes.

5. Confirm that the camshaft timing gear assembly revolves in the timing advance direction when the air pressure on the timing retard path is reduced.

   HINT:

   The lock pin is released and the camshaft timing gear revolves in the advance direction.

6. When the camshaft timing gear reaches the most advanced position, release the air pressure on the timing retard side path, and then release the air pressure on the timing advance side path.

   NOTICE:

   Camshaft timing gear assembly occasionally shifts to the retard side abruptly if the air pressure on the advance side path is released first. It often results in the breakage of the lock pin.

7. Remove the flange bolt and remove the camshaft timing gear assembly.

   NOTICE:

   1. Do not remove the other 4 bolts.
      
   2. When reusing the camshaft timing gear, unlock the lock pin inside the camshaft timing gear first.
      

1. Clamp the camshaft in a vice.

   NOTICE:

   Do not damage the camshaft.

2. Remove the bolt and the camshaft timing sprocket.

1. Using several steps, loosen and remove the 10 cylinder head bolts uniformly with an 8 mm bi-hexagon wrench in the sequence shown in the illustration. Remove the 10 cylinder head bolts and the plate washers.

   NOTICE:

   1. Do not drop the washers into the cylinder head.
      
   2. Head warpage or cracking could result from removing bolts in the wrong order.
      

1. Using SST, remove the oil filter.

   SST

   09228-06501
   

1. Using a 12 mm hexagon wrench, remove the oil filter union.

1. Using a knife, cut off the oil seal lip.

2. Using a screwdriver with its tip wrapped in protective tape, pry out the oil seal.

   NOTICE:

   After removal, check the crankshaft for any damage. If damaged, smooth the surface with 400-grit sandpaper.

1. Remove the oil pan drain plug and gasket.

2. Remove the 9 bolts and 2 nuts.

3. Insert the blade of an oil pan seal cutter between the No. 1 oil pan and No. 2 oil pan, and cut off the applied sealer and remove No. 2 oil pan.

   NOTICE:

   Do not damage oil pan No. 1 or oil pan No. 2.

1. Remove the bolt and 2 nuts.

2. Remove the oil strainer and the gasket.

1. Loosen and remove the 13 bolts uniformly in several steps.

2. Using a screwdriver, remove oil pan No. 1 by prying between the cylinder block and oil pan No. 1.

   NOTICE:

   Do not damage the contact surfaces of oil pan No. 1 or the cylinder block.

3. Remove the 2 O-rings from the cylinder block.

1. Remove the 4 stud bolts.

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

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

   HINT:

   1. Keep the bearing, connecting rod and cap together.
      
   2. Keep the piston and the connecting rod assemblies in the correct order so that they can be returned to their original locations when reassembled.
      

1. Using several steps, loosen and remove the 10 bearing cap sub-assembly bolts uniformly using 12 mm socket wrench in the sequence shown in the illustration.

2. Remove the bearing cap and the crankshaft.

NOTICE:

Keep the piston rings in the correct combination and correct order so that they can be returned to their original locations when reassembled.

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

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

1. Using SST, press out the piston pin out of the piston.

   SST

   09221-25026 (09221-00021, 09221-00030, 09221-00090, 09221-00150, 09221-00100)
   

   NOTICE:

   Keep the pistons, pins, rings, connecting rods and bearings in the correct order so that they can be returned to their original locations when reassembled.

1. Using "Torx" socket wrench E5, remove the 7 stud bolts.