Engine Unit Disassembly

Remove the bolt and cam position sensor.

Remove the 2 bolts, clamp and crank position sensor.

Disconnect the ventilation hose.

Remove the 13 bolts, 2 nuts, 2 washers, 4 nozzle holder clamp seats and cylinder head cover sub-assembly.

Remove the cylinder head cover gasket and No. 2 cylinder head cover gasket.

Remove the 2 engine cover joints.

Remove the oil filler cap and gasket.

Remove the drain plug and gasket.

Remove the 16 bolts and 2 nuts.

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

SST

09032-00100

NOTICE:

1. Use SST from the side of the engine.
   
2. Be careful not to damage the No. 2 oil pan flange.
   

Remove the 20 bolts and nut.

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

NOTICE:

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

HINT:

Tape the screwdriver tip before use.

Remove the 4 bolts, oil filter bracket and gasket.

Remove the 4 bolts, oil strainer and O-ring.

Using SST, remove the bolt holding the crankshaft.

SST

09213-58013
09330-00021

Insert the service bolt.

Recommended service bolt:

Item	Specified Condition
Thread diameter	12 mm (0.47 in.)
Thread pitch	1.5 mm (0.059 in.)
Bolt length	Approx. 30 to 38 mm (1.18 to 1.50 in.)

Using SST, remove the crankshaft pulley.

SST

09950-50013(09951-05010,09952-05010,09953-05020,09954-05021)

Remove the 7 bolts and water pump assembly.

Remove the gasket.

Using a 10 mm socket hexagon wrench, remove the timing chain cover plug and gasket.

Remove the 13 bolts and seal washer shown in the illustration.

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

HINT:

Tape the screwdriver tip before use.

NOTICE:

Do not damage the contact surfaces of the cylinder head, cylinder block and timing chain cover.

Remove the gasket and O-ring.

Using a screwdriver, pry out the oil seal.

HINT:

Tape the screwdriver tip before use.

NOTICE:

Do not damage the surface of the oil seal press fit hole.

Align the timing marks of the drive and driven gears (1 dot mark each) by turning the crankshaft with a wrench.

Install the service bolt.

Recommended service bolt:

Item	Specified Condition
Thread diameter	6 mm (0.24 in.)
Thread pitch	1 mm (0.04 in.)
Bolt length	16 to 18 mm (0.63 to 0.71 in.)

Torque:

1.5 N*m{15.3 kgf*cm, 13.3 in.*lbf}

HINT:

When removing the balancer assembly, make certain that the torsional spring force of the sub gear has been eliminated by installing the service bolt.

Uniformly loosen the 6 bolts in several steps, in the sequence shown in the illustration.

Remove the engine balancer assembly.

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

Move the stopper plate downward to set the lock, and insert SST into the stopper plate hole (*2).

SST

09240-00020(09242-00200)

Remove the 2 bolts and chain tensioner assembly.

Remove the tensioner slipper.

Remove the 2 bolts and vibration damper.

Remove the 4 bolts, camshaft timing sprocket, crankshaft timing sprocket and chain.

Using the crankshaft pulley bolt, set the No. 1 cylinder to 90° BTDC/compression.

Remove the 2 union bolts.

Using several steps, loosen and remove the 20 bearing cap bolts uniformly in the sequence shown in the illustration.

Remove the 8 No. 3 bearing caps, No. 1 bearing cap and 2 oil delivery pipes.

HINT:

Do not remove the No. 4 bearing cap.

Remove the camshaft.

Remove the No. 2 camshaft.

Remove the No. 2 bearing cap.

Remove the 16 No. 1 valve rocker arm sub-assemblies.

Uniformly loosen the 10 bolts in the sequence shown in the illustration. Remove the 10 cylinder head bolts and plate washers.

NOTICE:

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

Remove the cylinder head.

Remove the cylinder head gasket.

Remove the valve lash adjusters from the cylinder head.

HINT:

Arrange the removed parts in the correct order.

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

SST

09202-70020

Remove the retainer, compression spring, and valve.

HINT:

Arrange the removed parts in the correct order.

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

SST

09202-70020

Remove the retainer, compression spring, and valve.

HINT:

Arrange the removed parts in the correct order.

Using needle-nose pliers, remove the oil seals.

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

Gradually heat the cylinder head to approximately 80 to 100°C (176 to 212°F).

Using SST and a hammer, tap out the valve guide bush.

SST

09201-10000
09950-70010

Gradually heat the cylinder head to approximately 80 to 100°C (176 to 212°F).

Using SST and a hammer, tap out the valve guide bush.

SST

09201-10000
09950-70010

Remove the 2 connecting rod cap bolts.

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 to the connecting rod cap.

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

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

HINT:

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

Uniformly loosen the 10 bolts in several steps, in the sequence shown in the illustration.

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

HINT:

1. Keep the lower bearings and crankshaft bearing caps together.
   
2. Arrange the thrust washers in the correct order.
   

Remove the crankshaft bearing cap sub-assembly by prying between the crankshaft bearing cap sub-assembly and cylinder block with a screwdriver.

HINT:

Tape the screwdriver tip before use.

NOTICE:

Do not damage the contact surfaces of the cylinder block and crankshaft bearing cap sub-assembly.

Lift out the crankshaft.

Using a 6 mm hexagon wrench, remove the screw plug.

Remove the upper bearings and upper thrust washers from the cylinder block.

HINT:

Arrange the bearings and thrust washers in the correct order.

Remove the lower bearings from the crankshaft bearing cap sub-assembly.

HINT:

Arrange the bearings in the correct order.

Remove the rear oil seal from the crankshaft.

Using a "torx" socket wrench (T30), remove the 3 bolts and the crankshaft position sensor plate.

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

Using a piston ring expander, remove the oil ring rail.

Remove the oil ring expander by hand.

Remove the water drain cock sub-assembly from the cylinder block.

Remove the water drain cock plug from the water drain cock sub-assembly.

Check the fitting condition between the piston and piston pin.

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

   HINT:

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

Disconnect the connecting rod from the piston.

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





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





3. Using a brass bar and plastic hammer, 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.
      

Using a gasket scraper, remove the carbon from the piston top.

Using a groove cleaning tool or broken ring, clean the piston ring grooves.

Using solvent and a brush, thoroughly clean the piston.

NOTICE:

Do not use a wire brush.

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

Using a 5 mm hexagon wrench, remove the reflector plates.

Using a gasket scraper, remove all the gasket material from the top surface of the cylinder block.

Using a soft brush and solvent, thoroughly clean the cylinder block.