ENGINE UNIT > DISASSEMBLY

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

1. Remove the ventilation valve from the head cover.
   

1. Remove the 19 bolts, 2 nuts, cover and 2 gaskets.
   

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

2. Check that the timing marks of the camshaft timing gear and sprocket are aligned with the timing marks of the No. 1 bearing cap, as shown in the illustration.
   

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

   SST

   09213-54015   (91651-60855)
   09330-00021  
   

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

   SST

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

1. Remove the drain plug and gasket.
   

2. Remove the 20 bolts and 2 nuts.
   

3. Insert the blade of SST between the oil pans. Cut through the applied sealer and remove the oil pan.
   

   SST

   09032-00100  
   

   NOTICE:

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

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

1. Remove the 16 bolts and 2 nuts.
   

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

   HINT:

   Tape the screwdriver tip before use.

   NOTICE:

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

3. Remove the O-ring.
   

1. Remove the 19 bolts and 2 nuts as shown in the illustration.
   

2. 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:

   Be careful not to damage the contact surface of the cylinder head, cylinder block and timing chain cover.

3. Remove the 3 O-rings.
   

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

1. Remove the 8 bolts, water pump and gasket.
   

1. Using a screwdriver with its tip taped, pry out the oil seal.
   

1. Using a 27 mm socket wrench, remove the plug and gasket.
   

2. Remove the valve spring and relief valve.
   

1. Remove the 2 bolts, timing chain guide and O-ring.
   

NOTICE:

1. When the chain tensioner is removed, do not rotate the crankshaft.
   
2. When the chain is removed and the camshaft needs to be rotated, rotate the crankshaft 90° to the right.
   

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

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

3. Remove the bolt, nut, chain tensioner and gasket.
   

1. Remove the bolt and tensioner slipper.
   

1. Remove the bolt, nut and vibration damper.
   

1. Remove the crankshaft timing sprocket from the crankshaft.
   

1. Remove the bolt, oil jet and gasket.
   

1. Uniformly loosen the 21 bearing cap bolts in the several passes in the order shown in the illustration.
   

2. Remove the 9 bearing caps, oil delivery pipe, O-ring and 2 camshafts.
   

   NOTICE:

   1. Place the camshaft on a flat surface, maintain this position and loosen the bolts uniformly.
      
   2. Do not pry the camshaft with a tool by applying excessive force to it.
      
   3. Do not damage the reception part of the exhaust on the cylinder head side.
      

3. Remove the oil delivery pipe and O-ring from the bearing caps.
   

4. Remove the 9 bearing caps.
   

5. Remove the 2 camshafts.
   

1. Fix the camshaft with a vise and then remove the sprocket bolt and camshaft timing sprocket.
   

   NOTICE:

   Be careful not to damage the camshaft.

1. Remove the flange bolt of the camshaft timing gear.
   

   NOTICE:

   1. Be sure not to remove the other 3 bolts.
      
   2. If planning to reuse the gear, be sure to release the straight pin lock before installing the gear.
      

1. Using a 10 mm bi-hexagon wrench, uniformly loosen the 10 bolts in the sequence shown in the illustration. Remove the 10 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.
      

2. Remove the cylinder head and gasket.
   

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

2. Move the stopper plate upward to set the lock, and insert a hexagon wrench into the stopper plate's hole.
   

3. Remove the bolt and chain vibration damper.
   

1. Remove the 2 bolts and chain vibration damper.
   

1. Remove the hexagon wrench from the tensioner.
   

2. Remove the nut and chain tensioner.
   

1. Remove the bolt, balance shaft drive gear shaft and balance shaft drive gear.
   

2. Remove the No. 2 crankshaft timing sprocket and chain.
   

1. Remove the 2 bolts and No. 4 vibration damper.
   

1. Remove the 2 pulley set keys from the crankshaft.
   

1. Using SST, remove the oil filter.
   

   SST

   09228-07501  
   

1. Using a 27 mm socket wrench, remove the oil filter union.
   

1. Remove the oil filter bracket union bolt, gasket and oil filter union.
   

2. Remove the oil filter bracket and O-ring.
   

3. Remove the O-ring from the oil filter bracket union bolt.
   

1. Remove the 6 bolts.
   

2. Using a screwdriver with its tip taped, pry out the oil seal retainer.
   

HINT:

Each rocker arm must be reinstalled to its original location.

HINT:

Each valve stem cap must be reinstalled to its original location.

HINT:

Each lash adjuster must be reinstalled to its original location.

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

   SST

   09202-70020   (09202-00010)
   

2. Remove the retainer, compression spring, valve, valve spring and spring seat.
   

   HINT:

   Each intake valve must be reinstalled to its original location.

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

2. Remove the retainer, compression spring, valve, valve spring and spring seat.
   

   HINT:

   Each exhaust valve must be reinstalled to its original location.

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

1. Using an 8 mm hexagon wrench, remove the screw plug.
   

2. Remove the oil control valve filter and gasket.
   

1. Using a 10 mm hexagon wrench, remove the 3 screw plugs.
   

1. Using a 9 mm hexagon wrench, remove the screw plug.
   

1. 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 for ensuring the correct reassembly.

2. Remove the 10 connecting rod cap bolts.
   

3. Using the 2 removed connecting rod cap bolts, remove the connecting rod cab and lower bearing by wiggling the connecting rod cap right and left.
   

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

2. 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.
      

1. Check fit between the piston and piston pin.
   
   

   1. Try to move the piston back and forth on the piston pin.
      If any movement is felt, replace the piston and pin as a set.
      

2. Remove the piston rings.
   
   

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

   2. Remove the rail and expander by hand.
      

      HINT:

      Arrange the piston rings in correct order only.

3. Disconnect the connecting rod from the piston.
   
   

   1. Using a small screwdriver, pry off the snap ring 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-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.
         

1. Uniformly loosen the 10 bearing cap bolts in several passes in the sequence shown in the illustration.
   

   HINT:

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

2. Lift out the crankshaft.
   

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

   HINT:

   Arrange the main bearing caps, bearings and thrust washers in correct order.

1. Using a 5 mm hexagon wrench, remove the oil nozzle.
   

1. Remove the bolt.
   

2. Remove the balance shaft from the cylinder block.
   

   NOTICE:

   When removing the balance shaft, make sure to support the balance shaft with both hands and avoid scratching the balance shaft bearing on the cylinder block side.

1. Mount the head portion of the balance shaft in a vise.
   

   NOTICE:

   Be careful not to damage the balance shaft.

2. Remove the bolt.
   

3. Remove the No. 1 balance shaft driven gear (A), sliding key (B), No. 1 balance shaft thrust washer (C) and balance shaft thrust spacer (D).
   

1. Remove the 2 bolts.
   

2. Remove the balance shaft from the cylinder block.
   

   NOTICE:

   When removing the balance shaft, make sure to support the balance shaft with both hands and avoid scratching the balance shaft bearing on the cylinder block side.

1. Mount the head portion of the balance shaft in a vise.
   

   NOTICE:

   Be careful not to damage the balance shaft.

2. Remove the bolt.
   

3. Remove the No. 2 balance shaft driven gear (A) and No. 2 balance shaft thrust washer (B).