ENGINE UNIT > DISASSEMBLY

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1. Remove the 4 bolts and vacuum pump assembly.
   

2. Remove the No. 2 O-ring and No. 3 O-ring from the vacuum pump assembly.
   

   Text in Illustration 

   *1	No. 2 O-ring
   *2	No. 3 O-ring

1. Disconnect the knock control sensor connector.
   

2. Remove the bolt and knock control sensor from the cylinder block sub-assembly.
   

   NOTICE:

   If the knock control sensor has been struck or dropped, replace it.

1. Disconnect the oil pressure sender gauge assembly connector.
   

2. Using a 27 mm deep socket wrench, remove the oil pressure sender gauge assembly.
   

1. Disconnect the engine coolant temperature sensor connector.
   

2. Using SST, remove the engine coolant temperature sensor from the cylinder head sub-assembly.
   

   Text in Illustration 

   *1	Engine Coolant Temperature Sensor
   *2	Gasket

   SST

   09817-33191  
   

   NOTICE:

   If the engine coolant temperature sensor has been struck or dropped, replace it.

3. Remove the gasket from the engine coolant temperature sensor.
   

1. Remove the 2 engine cover joints.
   

1. Remove the 4 spark plugs from the cylinder head sub-assembly.
   

   NOTICE:

   If a spark plug has been struck or dropped, replace it.

   HINT:

   Arrange the removed parts in the correct order.

1. Remove the oil filler cap sub-assembly from the cylinder head cover sub-assembly.
   

2. Remove the gasket from the oil filler cap sub-assembly.
   

1. Disconnect the camshaft timing oil control valve assembly connector.
   

2. Remove the bolt and camshaft timing oil control valve assembly from the cylinder head cover sub-assembly.
   

   NOTICE:

   1. Do not allow foreign matter to contact the oil seal face of the camshaft timing oil control valve assembly (connecting surface with the cylinder head cover sub-assembly).
      
   2. If the camshaft timing oil control valve assembly has been struck or dropped, replace it.
      

3. Remove the O-ring from the camshaft timing oil control valve assembly.
   

   Text in Illustration 

   *1

   O-ring

1. Disconnect the camshaft position sensor connector.
   

2. Remove the bolt and camshaft position sensor from the cylinder head cover sub-assembly.
   

   NOTICE:

   If the camshaft position sensor has been struck or dropped, replace it.

1. Disconnect the camshaft position sensor connector.
   

2. Remove the bolt and camshaft position sensor from the cylinder head cover sub-assembly.
   

   NOTICE:

   If the camshaft position sensor has been struck or dropped, replace it.

1. Using a 19 mm deep socket wrench, remove the PCV valve (ventilation valve sub-assembly) from the cylinder head cover sub-assembly.
   

1. Remove the 8 bolts and 2 nuts.
   

   Text in Illustration 

   	Bolt
   	Nut

2. Remove the No. 1 ventilation case by prying between the No. 1 ventilation case and cylinder block sub-assembly with a screwdriver.
   

   NOTICE:

   Be careful not to damage the contact surfaces of the cylinder block sub-assembly and No. 1 ventilation case.

   HINT:

   Tape the screwdriver tip before use.

1. Disconnect the crankshaft position sensor connector.
   

2. Remove the bolt and crankshaft position sensor from the timing chain cover sub-assembly.
   

   NOTICE:

   If the crankshaft position sensor has been struck or dropped, replace it.

1. Using SST, hold the crankshaft pulley and loosen the crankshaft pulley set bolt. Further loosen the crankshaft pulley set bolt until 2 or 3 threads are screwed into the crankshaft.
   

   Text in Illustration 

   *a	Hold
   *b	Turn

   SST

   09213-54015  
   09330-00021  
   

   HINT:

   Part number of installation bolt for SST (crankshaft pulley holding tool): 91551-80650 (quantity: 2)

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

   Text in Illustration 

   *1	Crankshaft Pulley Set Bolt
   *a	Hold
   *b	Turn

   SST

   09950-50013   (09951-05010, 09952-05010, 09953-05020, 09954-05011)
   

   HINT:

   Apply lubricant to the threads and end of SST.

1. Remove the 17 bolts, 3 seal washers, cylinder head cover sub-assembly and cylinder head cover gasket.
   

   Text in Illustration 

   	Bolt
   	Bolt with Seal Washer

2. Remove the camshaft bearing cap oil hole gasket from the No. 1 camshaft bearing cap.
   

   Text in Illustration 

   *1	Camshaft Bearing Cap Oil Hole Gasket
   *a	Gasket

3. Remove the gasket from the No. 2 camshaft bearing cap.
   

1. Remove the 2 bolts and case separator from the cylinder head cover case sub-assembly.
   

2. Remove the oil separator gasket from the case separator.
   

3. Remove the O-ring from the case separator.
   

   Text in Illustration 

   *a

   O-ring

1. Using a screwdriver, pry out the 4 spark plug tube gaskets from the cylinder head cover sub-assembly.
   

   Text in Illustration 

   *a	Protective Tape

   NOTICE:

   Be careful not to damage the cylinder head cover sub-assembly.

   HINT:

   Tape the screwdriver tip before use.

1. Disconnect the camshaft timing oil control solenoid assembly connector.
   

2. Remove the 2 bolts and camshaft timing oil control solenoid assembly from the timing chain cover sub-assembly.
   

   NOTICE:

   If the camshaft timing oil control solenoid assembly has been struck or dropped, replace it.

3. Remove the O-ring from the camshaft timing oil control solenoid assembly.
   

   NOTICE:

   1. If the O-ring comes off in the timing chain cover sub-assembly, make sure to remove it.
      
   2. Do not drop the O-ring into the timing chain cover sub-assembly.
      

1. Remove the 4 bolts, timing chain cover plate and gasket.
   

1. Remove the 5 bolts and engine mounting bracket RH.
   

1. Remove the 17 bolts and 2 nuts.
   

   Text in Illustration 

   	Bolt
   	Nut

2. Remove the timing chain cover sub-assembly by prying between the timing chain cover sub-assembly and cylinder head sub-assembly, camshaft housing sub-assembly, cylinder block and stiffening crankcase assembly with a screwdriver as shown in the illustration.
   
   

   
   
   
   
   

   Text in Illustration 

   *a

   Protective Tape

   -

   -

   NOTICE:

   Be careful not to damage the contact surfaces of the cylinder head sub-assembly, camshaft housing sub-assembly, cylinder block, stiffening crankcase assembly or timing chain cover sub-assembly.

   HINT:

   Tape the screwdriver tip before use.

3. Remove the 2 oil pump gaskets and oil hole cover gasket from the stiffening crankcase assembly.
   

   Text in Illustration 

   *1	Oil Pump Gasket
   *2	Oil Hole Cover Gasket

1. Using a screwdriver and wooden block, pry out the timing chain cover oil seal.
   

   Text in Illustration 

   *a	Protective Tape
   *b	Wooden Block

   NOTICE:

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

   HINT:

   Tape the screwdriver tip before use.

1. Temporarily install the crankshaft pulley set bolt.
   
   

   
   
   
   
   

   Text in Illustration 

   *1	Crankshaft Pulley Key	-	-
   *a	Approximately 7°	*b	Approximately 32°
   *c	Timing Mark	-	-

2. Rotate the crankshaft clockwise and align the crankshaft pulley key as shown in the illustration.
   

3. Check that the timing marks on the camshaft timing exhaust gear assembly and camshaft timing gear assembly are as shown in the illustration.
   

   HINT:

   "A" is not a timing mark.

4. Remove the crankshaft pulley set bolt.
   

1. Remove the bolt and timing chain guide.
   

1. Allow the plunger to extend slightly, and then turn the stopper plate counterclockwise to release the lock. Once the lock is released, push the plunger into the No. 1 chain tensioner assembly.
   

   Text in Illustration 

   *a	Stopper Plate
   *b	Plunger

2. Turn the stopper plate clockwise to set the lock, and insert a pin into the stopper plate hole.
   

   Text in Illustration 

   *a

   Pin

3. Remove the 2 bolts, No. 1 chain tensioner assembly and gasket.
   

1. Remove the bolt and chain tensioner slipper.
   

1. Remove the chain sub-assembly.
   

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

1. Remove the crankshaft timing sprocket from the crankshaft.
   

1. Using a wrench to hold the hexagonal portion of the camshaft, remove the camshaft timing gear bolt and camshaft timing gear assembly.
   

   Text in Illustration 

   *a	Hold
   	Turn

   NOTICE:

   1. Be careful not to damage the cylinder head sub-assembly or spark plug tube with the wrench.
      
   2. Do not disassemble the camshaft timing gear assembly.
      

1. Using a wrench to hold the hexagonal portion of the No. 2 camshaft, remove the bolt and camshaft timing exhaust gear assembly.
   

   Text in Illustration 

   *a	Hold
   	Turn

   NOTICE:

   1. Be careful not to damage the cylinder head sub-assembly or spark plug tube with the wrench.
      
   2. Do not disassemble the camshaft timing exhaust gear assembly.
      

1. Remove the bolt and oil pipe sub-assembly from the No. 4 camshaft bearing cap.
   

1. Uniformly loosen and remove the 20 bolts in the order shown in the illustration.
   

2. Remove the camshaft housing sub-assembly by prying between the cylinder head sub-assembly and camshaft housing sub-assembly with a screwdriver.
   

   NOTICE:

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

   HINT:

   Tape the screwdriver tip before use.

1. Remove the 11 bolts in the order shown in the illustration.
   

2. Remove the No. 1 camshaft bearing cap, No. 2 camshaft bearing cap, No. 3 camshaft bearing cap and No. 4 camshaft bearing cap.
   

   HINT:

   Arrange the removed parts in the correct order.

1. Remove the camshaft from the camshaft housing sub-assembly.
   

1. Remove the No. 2 camshaft from the camshaft housing sub-assembly.
   

1. Remove the oil control valve filter from the No. 1 camshaft bearing cap.
   

1. Remove the No. 1 camshaft bearing from the No. 1 camshaft bearing cap.
   

1. Remove the No. 2 camshaft bearing from the camshaft housing sub-assembly.
   

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

   HINT:

   Arrange the removed parts in the correct order.

1. Remove the 16 valve lash adjuster assemblies from the cylinder head sub-assembly.
   

   HINT:

   Arrange the removed parts in the correct order.

1. Remove the 16 valve stem caps from the cylinder head sub-assembly.
   

   HINT:

   Arrange the removed parts in the correct order.

NOTICE:

If a camshaft housing stud bolt is deformed or its threads are damaged, replace it.

NOTICE:

It is not necessary to remove the camshaft bearing cap setting ring pin unless it is being replaced.

NOTICE:

It is not necessary to remove the camshaft housing straight pin unless it is being replaced.

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

   HINT:

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

   NOTICE:

   1. Be careful not to drop plate washers into the cylinder head sub-assembly.
      
   2. Cylinder head warpage or cracking may result from removing bolts in the incorrect order.
      

2. Remove the cylinder head sub-assembly.
   

1. Remove the cylinder head gasket from the cylinder block sub-assembly.
   

1. Remove the cylinder block water jacket spacer from the cylinder block sub-assembly.
   

   NOTICE:

   Be sure to remove the cylinder block water jacket spacer. If it is not removed, it may fall and become damaged when the cylinder block sub-assembly is inverted.

1. Connect a hose with an inside diameter of 15 mm (0.591 in.) to the pipe.
   

   Text in Illustration 

   *a	Pipe
   *b	Hose

2. Remove the oil filter drain plug from the oil filter cap assembly.
   

3. Insert the pipe with hose into the oil filter cap assembly.
   

   Text in Illustration 

   *1	Oil Filter Cap Assembly
   *2	O-ring
   *a	Valve
   *b	Hose

   NOTICE:

   Be sure to insert the pipe with the O-ring installed to the oil filter cap assembly.

   HINT:

   Place the hose end into a container before draining the engine oil from the hose.

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

   HINT:

   Pull the pipe with hose as shown in the illustration to remove it.

5. Using SST, remove the oil filter cap assembly.
   

   Text in Illustration 

   *1	Oil Filter Bracket Clip

   SST

   09228-06501  
   

   NOTICE:

   Do not remove the oil filter bracket clip.

6. Remove the oil filter element and O-ring from the oil filter cap assembly.
   

   Text in Illustration 

   *1	Oil Filter Element
   *2	Oil Filter Cap Assembly
   *3	O-ring

   NOTICE:

   Do not use any tools to remove the O-ring in order to prevent the oil filter cap assembly from being damaged. Be sure to remove it by hand.

1. Remove the oil pan drain plug and gasket from the oil pan sub-assembly.
   

1. Remove the 11 bolts and 2 nuts.
   

   Text in Illustration 

   *A	Type A
   *B	Type B
   	Bolt
   	Nut

2. Insert the blade of an oil pan seal cutter between the oil pan sub-assembly and stiffening crankcase assembly, cut through the applied sealer and remove the oil pan sub-assembly.
   

   NOTICE:

   1. Be careful not to damage the stiffening crankcase assembly contact surface of the oil pan sub-assembly.
      
   2. Be careful not to damage the oil pan sub-assembly flange.
      

1. Remove the 3 bolts, oil strainer sub-assembly and gasket.
   

1. Disconnect the engine oil level sensor connector.
   

2. Remove the clip from the engine oil level sensor.
   

3. Remove the 2 bolts.
   

4. Disengage the clamp to remove the engine oil level sensor.
   

1. Remove the 2 bolts and oil level sensor bracket from the stiffening crankcase assembly.
   

1. Remove the clamp from the No. 1 oil pan baffle plate.
   

2. Remove the 4 bolts and No. 1 oil pan baffle plate.
   

1. Using a dial indicator, measure the backlash of the crankshaft and balance shaft as shown in the illustration.
   

   Standard Backlash:

   0.05 to 0.20 mm (0.00197 to 0.00787 in.)
   

   Maximum Backlash:

   0.20 mm (0.00787 in.)
   

   If the backlash is more than the maximum, replace the engine balancer assembly.
   

1. Remove the 7 bolts and engine balancer assembly from the stiffening crankcase assembly.
   

   NOTICE:

   Do not disassemble the engine balancer assembly.

1. Using a dial indicator, measure the thrust clearance while moving the No. 1 balance shaft back and forth.
   

   Standard Thrust Clearance:

   0.05 to 0.09 mm (0.00197 to 0.00354 in.)
   

   Maximum Thrust Clearance:

   0.09 mm (0.00354 in.)
   

   If the thrust clearance is more than the maximum, replace the engine balancer assembly.
   

1. Using a dial indicator, measure the thrust clearance while moving the No. 2 balance shaft back and forth.
   

   Standard Thrust Clearance:

   0.05 to 0.09 mm (0.00197 to 0.00354 in.)
   

   Maximum Thrust Clearance:

   0.09 mm (0.00354 in.)
   

   If the thrust clearance is more than the maximum, replace the engine balancer assembly.
   

1. Remove the 7 bolts.
   

2. Using a screwdriver, remove the stiffening crankcase assembly by prying between the stiffening crankcase assembly and cylinder block sub-assembly at the places shown in the illustration.
   

   Text in Illustration 

   *a	LH Side
   *b	RH Side

   NOTICE:

   Be careful not to damage the contact surfaces of the cylinder block sub-assembly and stiffening crankcase assembly.

   HINT:

   Tape the screwdriver tip before use.

1. Remove the oil filter bracket clip from the stiffening crankcase assembly.
   

NOTICE:

If a stiffening crankcase stud bolt is deformed or its threads are damaged, replace it.

NOTICE:

It is not necessary to remove the stiffening crankcase ring pin unless it is being replaced.

1. Remove the rear engine oil seal from the cylinder block sub-assembly.