Engine Unit Disassembly

Remove the oil filler cap.

Remove the oil filler cap gasket.

Remove the ventilation valve.

Remove the spark plugs.

Using SST, remove the oil filter.

SST

09228-06501

HINT:

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

Remove the oil filter union, plate washer, nut, oil cooler and O-ring.

Remove the union bolt.

Remove the 2 bolts and disconnect the 2 engine wires.

Remove the 8 bolts, 2 nuts, and the cylinder head cover.

Remove the cylinder head cover gasket.

Lift the engine upward using the chain block.

NOTICE:

Do not lift the engine more than necessary.

Remove the bolt, nut and V-ribbed belt tensioner.

Remove the wire harness clamp.

Separate the wire harness from the wire harness clamp bracket.

Remove the 2 bolts and sensor.

Remove the bolt and sensor.

Using SST, fix the pulley in place and loosen the pulley bolt.

SST

09213-54015(91651-60855)
09330-00021

Using SST, remove the pulley bolt and pulley.

SST

09950-50013(09951-05010,09952-05010,09953-05020,09954-05021)
09950-40011(09957-04010)

HINT:

If necessary, remove the pulley and pulley bolt using SST.

Disconnect the camshaft timing oil control valve assembly connector.

Remove the bolt and camshaft timing oil control valve assembly.

Remove the 2 nuts, tensioner and gasket.

NOTICE:

Do not turn the crankshaft without the chain tensioner.

Using SST, remove the 4 bolts and water pump pulley.

SST

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

Remove the clamp of the crankshaft position sensor from the water pump.

Disconnect the wire of the crankshaft position sensor from the clamp bracket.

Remove the 4 bolts, 2 nuts and clamp bracket.

Using a screwdriver, pry between the water pump and cylinder block, and then remove the water pump.

HINT:

Tape the screwdriver tip before use.

NOTICE:

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

Remove the oil pan drain plug and gasket.

Remove the 12 bolts and 2 nuts.

Insert the blade of oil pan seal cutter between the crankcase and oil pan. Cut through the sealer and remove the oil pan.

NOTICE:

Be careful not to damage the contact surfaces of the crankcase, chain cover and oil pan.

Using a E10 "TORX" socket, remove the stud bolt for the drive belt tensioner from the cylinder block.

Remove the 12 bolts and 2 nuts.

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.

HINT:

Tape the screwdriver tip before use.

Using a screwdriver and a hammer, remove the oil seal.

Remove the crankshaft position sensor plate.

Remove the bolt and timing chain guide.

Remove the bolt and chain tensioner slipper.

Remove the 2 bolts and chain vibration damper.

Remove the chain sub-assembly.

Remove the crankshaft timing sprocket.

Turn the crankshaft by 90° counterclockwise to align the adjusting hole of the oil pump drive shaft sprocket with the groove of the oil pump.

Insert a 4 mm diameter bar into the adjusting hole of the oil pump drive shaft sprocket to lock the gear in position, and then remove the nut.

Remove the bolt, chain tensioner plate and spring.

Remove the chain tensioner, oil pump driven sprocket and chain.

Remove the 2 pulley set keys from the crankshaft.

Using several steps, uniformly loosen and remove the 10 bearing cap bolts in the sequence shown in the illustration.

Remove the 5 bearing caps.

Using several steps, uniformly loosen and remove the 10 bearing cap bolts in the sequence shown in the illustration.

Remove the 5 bearing caps.

Remove the No. 2 camshaft bearing.

Clamp the camshaft in a vise.

Remove the flange bolt of the camshaft timing sprocket.

Clamp the camshaft in a vise, and make sure that the camshaft timing gear does not rotate.

Cover all the oil ports except the advance side port shown in the illustration with vinyl tape.

Apply air pressure of 100 kPa (1.0 kgf/cm², 14 psi) to the oil path, then turn the camshaft timing gear in the advance direction (counterclockwise) by hand.

CAUTION:

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

HINT:

Depending on the air pressure, the camshaft timing gear will turn to the advance angle side without applying force by hand. Also, if the pressure is difficult to apply because of air leakage from the port, the lock may be difficult to release.

Remove the flange bolt of the camshaft timing gear.

NOTICE:

1. Be sure not to remove the other 4 bolts.
   
2. If planning to reuse the gear, be sure to release the straight pin lock before installing the gear.
   

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

NOTICE:

Head warpage or cracking could result from removing the bolts in the wrong order.

Using a screwdriver with its tip wrapped with tape, pry between the cylinder head and cylinder block, and remove the cylinder head.

NOTICE:

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

Remove the cylinder head gasket.

Using needle-nose pliers, remove the cylinder block water jacket spacer.

NOTICE:

Be sure to remove the water jacket spacer if turning the cylinder block upside down.

Using an 8 mm socket hexagon wrench, remove the plug and filter.

Remove the 3 bolts, oil pump and gasket.

Uniformly loosen and remove the 8 bolts in the sequence shown in the illustration.

Remove the No. 1 and No. 2 balanceshafts.

Remove the balanceshaft bearings.

Using a knife, cut off the oil seal lip.

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.

Uniformly loosen and remove the 11 bolts in the sequence shown in the illustration.

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.

Remove the O-ring from the cylinder block.

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

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

HINT:

The matchmarks on the connecting rods and caps are provided for ensuring the correct reassembly.

Using a 12 mm socket wrench, uniformly loosen the 2 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 in the connecting rod cap.

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.
   

Remove the connecting rod bearings.

HINT:

Arrange the removed parts in the correct order.

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

Remove the oil ring rail and oil ring expander by hand.

HINT:

Arrange the removed parts in the correct order.

Using a screwdriver, pry out the 2 snap rings.

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

Using a plastic 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.
   

Uniformly loosen and remove the 10 main bearing cap bolts in the sequence shown in the illustration.

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

NOTICE:

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

HINT:

1. Keep the lower bearing and main bearing cap together.
   
2. Arrange the main bearing caps in the correct order.
   

Lift out the crankshaft.

Remove the upper thrust washers from the cylinder block.

Remove the 5 upper main bearings from the cylinder block.

HINT:

Arrange the bearings in the correct order.

Remove the 5 lower main bearings from the 5 main bearing caps.

HINT:

Arrange the bearings in the correct order.

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