Engine Unit Disassembly

Remove the oil filler cap sub-assembly.

Remove the 6 spark plugs.

Remove the drain plug and gasket.

Remove the ventilation valve sub-assembly.

Remove the 4 bolts and 4 camshaft position sensors.

Remove the 4 bolts and 4 camshaft timing oil control valves.

Remove the 2 bolts, 4 nuts and water outlet.

Remove the 2 gaskets and O-ring.

Remove the bolt.

Remove the 2 oil pipe unions and oil pipe.

Remove the oil control valve filter RH and gaskets.

Remove the 12 bolts, cylinder head cover and gasket.

HINT:

Make sure the removed parts are returned to the same locations they were removed from.

Remove the 2 oil pipe unions, gaskets and oil pipe.

Remove the oil control valve filter LH and gaskets.

Remove the 12 bolts, cylinder head cover and gasket.

HINT:

Make sure the removed parts are returned to the same locations they were removed from.

Remove the 6 bolts and mounting bracket.

Remove the 2 nuts, water inlet, and thermostat.

Remove the gasket.

Separate the No. 1 water by-pass hose.

Remove the 2 bolts, nut, and water inlet housing.

Remove the drain cock plug.

Remove the drain cock.

Remove the 2 O-rings.

Connect the hose to a pipe.

HINT:

The drain pipe is supplied with the oil filter element.

Remove the oil filter drain plug and O-ring, insert the drain pipe into the oil filter cap, and drain the engine oil into a container.

Make sure that oil is completely drained, and remove the pipe and O-ring.

HINT:

Be sure to turn the pipe in the direction indicated by the arrow to remove it.

Using SST, remove the oil filter cap together with the oil filter element.

SST

09228-06501

Remove the oil filter element and 2 O-rings from the oil filter cap.

NOTICE:

Be sure to remove the O-ring (for the cap) by hand, without using any tools, to prevent damage to the groove for the O-ring on the cap.

Remove the 16 bolts and 2 nuts.

Insert the blade of an oil pan seal cutter between the oil pans, cut through the applied sealer and remove the oil pan.

NOTICE:

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

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

Remove the 16 bolts and 2 nuts.

HINT:

Be sure to clean the bolts and stud bolts and check the threads for cracks or other damage.

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 2 O-rings from the oil pump.

Remove the 7 bolts and baffle plate.

Using SST, hold the crankshaft pulley and loosen the pulley bolt. Continue to loosen the bolt until only 2 or 3 threads are screwed into the crankshaft.

SST

09213-70011(09213-70020)
09330-00021

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

SST

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

Remove the 16 bolts, water pump and water pump gasket.

Remove the 6 bolts.

Using a screwdriver, pry out the oil seal retainer.

HINT:

Tape the screwdriver tip before use.

Remove the 23 bolts and 2 nuts as 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.

Temporarily tighten the pulley set bolt.

Set the timing mark on the crank angle sensor plate to the RH block bore center line (TDC / compression).

Check that the timing marks of the camshaft timing gears are aligned with the timing marks of the bearing cap as shown in the illustration. If not, turn the crankshaft 1 revolution (360°) and align the timing marks as in the previous step.

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

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

Remove the 2 bolts and chain tensioner.

Turn the crankshaft counterclockwise 10° to loosen the chain of the crankshaft timing gear.

Remove the chain from the crankshaft timing gear and place it on the crankshaft.

Turn the camshaft timing gear on the RH bank clockwise (approximately 60°) and set it as shown in the illustration. Be sure to loosen the chain between the center banks.

Remove the chain.

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

Remove the 2 bolts and vibration damper.

Remove the 2 chain vibration dampers.

Remove the pulley set bolt.

Remove the crankshaft timing gear from the crankshaft.

Remove the 2 pulley set keys from the crankshaft.

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

Hold the hexagonal portion of the camshaft with a wrench, and remove the 2 bolts and 2 camshaft timing gears.

NOTICE:

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

Remove the No. 2 chain.

Remove the bolt and chain tensioner.

Remove the 3 gaskets.

Make sure that the knock pin of the camshaft is positioned as shown in the illustration.

Uniformly loosen and remove the 8 bearing cap bolts in several steps and in the sequence shown in the illustration.

Uniformly loosen and remove the 12 bearing cap bolts in several steps and in the sequence shown in the illustration.

NOTICE:

Uniformly loosen the bolts while keeping the camshaft level.

Remove the 5 bearing caps.

Remove the No. 1 camshaft.

Remove the No. 2 camshaft.

Remove the camshaft housing by prying between the cylinder head and camshaft housing with a screwdriver.

NOTICE:

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

HINT:

Tape the screwdriver tip before use.

While pushing down the chain tensioner, insert a pin of φ1.0 mm (0.039 in.) into the hole to fix it in place.

Hold the hexagonal portion of the camshaft with a wrench and remove the 2 bolts and 2 camshaft timing gears.

NOTICE:

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

Remove the No. 2 chain.

Remove the bolt and chain tensioner.

Remove the 3 gaskets.

Make sure that the knock pin of the camshaft is positioned as shown in the illustration.

Uniformly loosen and remove the 8 bearing cap bolts in several steps and in the sequence shown in the illustration.

Uniformly loosen and remove the 13 bearing cap bolts in several steps and in the sequence shown in the illustration.

NOTICE:

Uniformly loosen the bolts while keeping the camshaft level.

Remove the 5 bearing caps.

Remove the No. 3 camshaft.

Remove the No. 4 camshaft.

Remove the camshaft housing by prying between the cylinder head and camshaft housing with a screwdriver.

NOTICE:

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

HINT:

Tape the screwdriver tip before use.

Remove the 24 valve rocker arms.

HINT:

Arrange the removed parts in the correct order.

Remove the 24 valve lash adjusters from the cylinder head.

HINT:

Arrange the removed parts in the correct order.

Using a 10 mm bi-hexagon wrench, uniformly loosen the 8 bolts in the sequence shown in the illustration. Remove the 8 cylinder head bolts and plate washers.

NOTICE:

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

HINT:

Be sure to keep the removed parts separate for each installation position.

Remove the cylinder head and gasket.

Uniformly loosen and remove the 2 bolts in the sequence shown in the illustration.

Using a 10 mm bi-hexagon wrench, uniformly loosen the 8 bolts in the sequence shown in the illustration. Remove the 8 cylinder head bolts and plate washers.

NOTICE:

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

HINT:

Be sure to keep the removed parts separate for each installation position.

Remove the cylinder head and gasket.

Disconnect the knock sensor wire.

Remove the 2 bolts and water outlet pipe.

Disconnect the water by-pass hose.

Remove the valve stem caps 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 lock.

SST

09202-70020(09202-00010)

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 lock.

SST

09202-70020(09202-00010)

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 magnet hand, remove the valve spring seat by blowing air onto it.

Using a 10 mm hexagon wrench, remove the 4 screw plugs and 4 gaskets.

Using a 14 mm hexagon wrench, remove the 2 screw plugs and 2 gaskets.

NOTICE:

If water leaks from the No. 2 screw plug or the plug is corroded, replace it.

Remove the bolt and crank position sensor.

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

Standard thrust clearance:

0.15 to 0.40 mm (0.0059 to 0.0157 in.)

Maximum thrust clearance:

0.50 mm (0.0197 in.)

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

NOTICE:

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

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.

Clean the crank pin and bearing.

Check the crank pin and bearing for pitting and scratches.

Lay a strip of Plastigage on the crank pin.

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

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

NOTICE:

Do not turn the crankshaft.

Torque:

25 N*m{255 kgf*cm, 18 ft.*lbf}

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

Retighten the cap bolts by 90° as shown.

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

NOTICE:

Do not turn the crankshaft.

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.

Measure the Plastigage at its widest point.

Standard oil clearance:

0.045 to 0.067 mm (0.0018 to 0.0026 in.)

Maximum oil clearance:

0.070 mm (0.0028 in.)

HINT:

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 1, 2, 3 and 4 mark on its surface.

Reference:

Connecting rod big end inside diameter:

Mark	Thickness
1	56.000 to 56.006 mm (2.2047 to 2.2050 in.)
2	56.007 to 56.012 mm (2.2050 to 2.2052 in.)
3	56.013 to 56.018 mm (2.2052 to 2.2054 in.)
4	56.019 to 56.024 mm (2.2055 to 2.2057 in.)

Standard sized bearing center wall thickness:

Mark	Thickness
1	1.481 to 1.484 mm (0.0583 to 0.0584 in.)
2	1.484 to 1.487 mm (0.0584 to 0.0585 in.)
3	1.487 to 1.490 mm (0.0585 to 0.0587 in.)
4	1.490 to 1.493 mm (0.0587 to 0.0588 in.)

Crankshaft pin diameter:

52.992 to 53.000 mm (2.0863 to 2.0866 in.)

Completely remove the Plastigage.

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

Push the piston, connecting rod 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 in the correct order.
   

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.)

Standard thrust washer thickness:

2.43 to 2.48 mm (0.0957 to 0.0976 in.)

Uniformly loosen and remove the 8 main bearing cap bolts and seal washers in several steps, in the sequence shown in the illustration.

Uniformly loosen the 16 bearing cap bolts in several steps, in the sequence shown in the illustration.

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

NOTICE:

1. Pry up the main bearing caps little by little to the right and left in turns.
   
2. Be careful not to damage the joint surfaces of the cylinder block and main bearing caps.
   

Clean each main journal and bearing.

Check each main journal and bearing for pitting and scratches.

HINT:

If the journal or bearing is damaged, replace the bearing.

Place the crankshaft on the cylinder block.

Lay a strip of Plastigage across each journal.

Examine the front marks and numbers and install the bearing caps on the cylinder block.

HINT:

A number is marked on each main bearing cap to indicate the installation position.

Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts.

Place the crankshaft bearing cap on the cylinder block.

Install the main bearing cap by hand until the clearance between the main bearing cap and the cylinder block is less than 6 mm (0.23 in.) by marking the 2 internal bearing cap bolts as a guide.

Bolt length:

100 to 102 mm (3.94 to 4.02 in.)

Using a plastic-faced hammer, lightly tap the bearing cap to ensure a proper fit.

Apply a light coat of engine oil to the threads and under the heads of the 8 main bearing cap bolts.

Install the 8 main bearing cap bolts to the outside positions.

Bolt length:

105.5 to 107.5 mm (4.15 to 4.23 in.)

HINT:

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

Step 1

1. Install and uniformly tighten the 16 main bearing cap bolts in the sequence shown in the illustration.
   

   Torque:

   61 N*m{622 kgf*cm, 45 ft.*lbf}

   HINT:

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

   NOTICE:

   Do not turn the crankshaft.

Step 2

1. Mark the front of the bearing cap bolts with paint.
   

2. Retighten the bearing cap bolts by 90° as shown in the order shown in step 1.
   

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

Install and uniformly tighten the 8 main bearing cap bolts in several steps and in the sequence shown in the illustration.

Torque:

52 N*m{530 kgf*cm, 38 ft.*lbf}

Bolt length:

45 mm (1.77 in.) for bolt A

30 mm (1.18 in.) for except bolt A

Remove the 24 bolts and bearing cap bolts.

Completely remove the Plastigage.

If replacing a bearing, replace it with one that has the same number. If the number of the bearing cannot be determined, select the correct bearing by adding together the numbers imprinted on the cylinder block and crankshaft, then refer to the table below for the appropriate bearing number. There are 5 sizes of standard bearings, marked "1", "2", "3", "4" and "5" accordingly.

Journal bearing:

Bearing to be Used	Cylinder Block Number Mark + Crankshaft Number Mark
1	0 to 5
2	6 to 11
3	12 to 17
4	18 to 23
5	24 to 28

Standard crankshaft main journal diameter:

Mark	Specified Condition
00	60.999 to 61.000 mm (2.4015 to 2.4016 in.)
01	60.998 to 60.999 mm (2.4015 to 2.4015 in.)
02	60.997 to 60.998 mm (2.4015 to 2.4015 in.)
03	60.996 to 60.997 mm (2.4014 to 2.4015 in.)
04	60.995 to 60.996 mm (2.4014 to 2.4014 in.)
05	60.994 to 60.995 mm (2.4013 to 2.4014 in.)
06	60.993 to 60.994 mm (2.4013 to 2.4013 in.)
07	60.992 to 60.993 mm (2.4013 to 2.4013 in.)
08	60.991 to 60.992 mm (2.4012 to 2.4013 in.)
09	60.990 to 60.991 mm (2.4012 to 2.4012 in.)
10	60.989 to 60.990 mm (2.4011 to 2.4012 in.)
11	60.988 to 60.989 mm (2.4011 to 2.4011 in.)

Standard upper bearing center wall thickness No. 1 and No. 4 journal:

Mark	Specified Condition
1	2.500 to 2.503 mm (0.0984 to 0.0985 in.)
2	2.503 to 2.506 mm (0.0985 to 0.0987 in.)
3	2.506 to 2.509 mm (0.0987 to 0.0988 in.)
4	2.509 to 2.512 mm (0.0988 to 0.0989 in.)
5	2.512 to 2.515 mm (0.0989 to 0.0990 in.)

No. 2 and No. 3 journal:

Mark	Specified Condition
1	2.478 to 2.481 mm (0.0976 to 0.0977 in.)
2	2.481 to 2.484 mm (0.0977 to 0.0978 in.)
3	2.484 to 2.487 mm (0.0978 to 0.0979 in.)
4	2.487 to 2.490 mm (0.0979 to 0.0980 in.)
5	2.490 to 2.493 mm (0.0980 to 0.0981 in.)

Standard lower bearing center wall thickness No. 1 and No. 4 journal:

Mark	Specified Condition
1	2.478 to 2.481 mm (0.0976 to 0.0977 in.)
2	2.481 to 2.484 mm (0.0977 to 0.0978 in.)
3	2.484 to 2.487 mm (0.0978 to 0.0979 in.)
4	2.487 to 2.490 mm (0.0979 to 0.0980 in.)
5	2.490 to 2.493 mm (0.0980 to 0.0981 in.)

No. 2 and No. 3 journal:

Mark	Specified Condition
1	2.500 to 2.503 mm (0.0984 to 0.0985 in.)
2	2.503 to 2.506 mm (0.0985 to 0.0987 in.)
3	2.506 to 2.509 mm (0.0987 to 0.0988 in.)
4	2.509 to 2.512 mm (0.0988 to 0.0989 in.)
5	2.512 to 2.515 mm (0.0989 to 0.0990 in.)

Lift out the crankshaft.

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 2 water drain cocks from the cylinder block.

Remove the water drain cock plugs from the water drain cocks.

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

Check the oil nozzles for damage or clogging.
If necessary, replace the oil nozzle.

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

Using a piston ring expander, remove the 2 side rails.

Remove the oil ring expander by hand.

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°C (176°F).
   





3. Using a brass bar and plastic-faced 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.
      

Clean the piston.

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





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





3. Using solvent and a brush, thoroughly clean the piston.
   

   NOTICE:

   Do not use a wire brush.