GSIC - Global Service Information Center

# ENGINE UNIT > DISASSEMBLY

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1. REMOVE OIL FILLER CAP

2. REMOVE VENTILATION VALVE

3. REMOVE CYLINDER HEAD COVER

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

4. REMOVE CRANKSHAFT PULLEY

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

1. 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.

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

   SST
     09213-54015 (91651-60855)
     09330-00021

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

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

5. REMOVE NO. 2 OIL PAN

1. Remove the drain plug and gasket.

1. Remove the 20 bolts and 2 nuts.

1. 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.

6. REMOVE OIL STRAINER

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

7. REMOVE NO. 1 OIL PAN

1. Remove the 16 bolts and 2 nuts.

1. 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.

1. Remove the O-ring.

8. REMOVE TIMING CHAIN COVER

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

1. 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.

1. Remove the 3 O-rings.

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

9. REMOVE WATER PUMP

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

10. REMOVE TIMING CHAIN COVER OIL SEAL

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

11. REMOVE OIL PUMP RELIEF VALVE

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

1. Remove the valve spring and relief valve.

12. REMOVE TIMING CHAIN GUIDE

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

13. REMOVE TIMING CHAIN TENSIONER

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 degrees to the right.

1. 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 a hexagon wrench into the stopper plate's hole.

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

14. REMOVE CHAIN TENSIONER SLIPPER

1. Remove the bolt and tensioner slipper.

15. REMOVE VIBRATION DAMPER

1. Remove the 2 bolts and vibration damper.

16. REMOVE TIMING CHAIN

17. REMOVE CRANKSHAFT TIMING SPROCKET

18. REMOVE CRANKSHAFT POSITION SENSOR PLATE

19. REMOVE CRANKSHAFT PULLEY SET KEY

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

20. REMOVE OIL JET

1. Remove the bolt, oil jet and gasket.

21. REMOVE CAMSHAFT

1. Uniformly loosen the 21 bearing cap bolts in several passes in the order shown in the illustration. Then remove the oil delivery pipe, O-ring and 9 bearing caps.

1. 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.

22. REMOVE CAMSHAFT TIMING SPROCKET

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.

23. REMOVE CAMSHAFT TIMING GEAR

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.

24. REMOVE CYLINDER HEAD

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.

1. Remove the cylinder head and gasket.

25. REMOVE OIL FILTER

1. Using SST, remove the oil filter.

   SST
     09228-07501

26. REMOVE OIL FILTER UNION

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

27. REMOVE OIL FILTER BRACKET

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

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

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

28. REMOVE ENGINE REAR OIL SEAL RETAINER

1. Remove the 6 bolts.

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

29. REMOVE VALVE ROCKER ARM

HINT:

  Each rocker arm must be reinstalled to its original location.

30. REMOVE VALVE STEM CAP

HINT:

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

31. REMOVE VALVE LASH ADJUSTER

HINT:

  Each lash adjuster must be reinstalled to its original location.

32. REMOVE INTAKE VALVE

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

   SST
     09202-70020 (09202-00010)

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

   HINT:
     Each intake valve must be reinstalled to its original location.

33. REMOVE EXHAUST VALVE

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

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

   HINT:
     Each exhaust valve must be reinstalled to its original location.

34. REMOVE VALVE STEM OIL SEAL

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

35. REMOVE OIL CONTROL VALVE FILTER

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

1. Remove the oil control valve filter and gasket.

36. REMOVE NO. 1 HEAD STRAIGHT SCREW PLUG

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

37. REMOVE NO. 2 HEAD STRAIGHT SCREW PLUG

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

38. REMOVE CONNECTING ROD CAP

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.

1. Remove the 2 connecting rod cap bolts.

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

39. REMOVE PISTON WITH CONNECTING ROD

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

1. 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.

40. REMOVE PISTON PIN

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.

1. 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.

1. 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.

41. REMOVE CRANKSHAFT

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

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

1. Lift out the crankshaft.

1. 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.

42. REMOVE CYLINDER BLOCK WATER DRAIN COCK

43. REMOVE OIL NOZZLE

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