Part 2
ENGINE UNIT DISASSEMBLY continued
44. REMOVE CAMSHAFT BEARING CAP
a. Remove the 3 gaskets.
b. Uniformly loosen and remove the 9 bearing cap bolts in the sequence shown in the illustration.
c. Uniformly loosen and remove the 14 bearing cap bolts in the sequence shown in the illustration.
NOTICE: Uniformly loosen the bolts while keeping the camshaft level.
d. Remove the 6 bearing caps.
45. REMOVE CAMSHAFT
a. Remove the camshaft.
46. REMOVE NO.2 CAMSHAFT
a. Remove the No.2 camshaft.
47. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY RH
a. Remove the camshaft housing sub-assembly RH by prying between the cylinder head and camshaft housing sub-assembly RH 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.
48. REMOVE NO.2 CAMSHAFT TIMING GEARS AND CHAIN (for Bank 2)
a. While pushing down the plunger, insert a pin of 1.0 mm (0.039 inch) into the hole to fix the plunger.
b. Hold the hexagonal portion of the camshaft with a wrench, and remove the 2 bolts and 2 camshaft timing gear assemblies.
NOTICE:
^ Be careful not to damage the cylinder head with the wrench.
^ Do not disassemble the camshaft timing gear assembly.
c. Remove the No.2 chain.
49. REMOVE NO.3 CHAIN TENSIONER ASSEMBLY
a. Remove the bolt and chain tensioner No.3.
50. REMOVE CAMSHAFT BEARING CAP
a. Remove the 3 gaskets.
b. Uniformly loosen and remove the 8 bearing cap bolts in the sequence shown in the illustration.
c. Uniformly loosen and remove the 12 bearing cap bolts in the sequence shown in the illustration.
NOTICE: Uniformly loosen the bolts while keeping the camshaft level.
d. Remove the 5 bearing caps.
51. REMOVE NO.4 CAMSHAFT SUB-ASSEMBLY
a. Remove the No.4 camshaft sub-assembly
52. REMOVE NO.3 CAMSHAFT SUB-ASSEMBLY
a. Remove the No.3 camshaft sub-assembly
53. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY LH
a. Remove the camshaft housing sub-assembly LH by prying between the cylinder head and camshaft housing sub-assembly LH 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.
54. REMOVE NO.1 VALVE ROCKER ARM SUB-ASSEMBLY
a. Remove the 24 valve rocker arm sub-assemblies.
HINT: Arrange the removed parts in the correct order.
55. REMOVE VALVE LASH ADJUSTER ASSEMBLY
a. Remove the 24 valve lash adjusters from the cylinder head.
HINT: Arrange the removed parts in the correct order.
56. REMOVE CYLINDER HEAD SUB-ASSEMBLY LH
a. Uniformly loosen and remove the bolts in the sequence shown in the illustration.
b. 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:
^ Be careful not to drop washers into the cylinder head.
^ Head warpage or cracking could result from removing bolts in an incorrect order.
HINT: Be sure to keep separate the removed parts for each installation position.
c. Remove the cylinder head and gasket.
57. REMOVE CYLINDER HEAD SUB-ASSEMBLY RH
a. 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:
^ Be careful not to drop washers into the cylinder head.
^ Head warpage or cracking could result from removing bolts in an incorrect order.
HINT: Be sure to keep separate the removed parts for each installation position.
b. Remove the cylinder head and gasket.
58. REMOVE CYLINDER BLOCK WATER JACKET SPACER LH
a. Using needle-nose pliers, remove the cylinder block water jacket spacer LH.
NOTICE: Be sure to remove the water jacket spacer if turning the cylinder block cover.
59. REMOVE CYLINDER BLOCK WATER JACKET SPACER RH
a. Using needle-nose pliers, remove the cylinder block water jacket spacer RH.
NOTICE: Be sure to remove the water jacket spacer if turning the cylinder block cover.
60. REMOVE WATER OUTLET PIPE SUB-ASSEMBLY
a. Separate the knock sensor wire.
b. Remove the 2 bolts and water outlet pipe.
61. REMOVE VALVE STEM CAP
a. Remove the valve stem caps from the cylinder head.
HINT: Arrange the removed parts in the correct order.
62. REMOVE INTAKE VALVE
a. Using SST and wooden blocks, compress the compression spring and remove the valve retainer locks.
SST 09202-70020 (09202-00010)
b. Remove the retainer, compression spring, and valve.
HINT: Arrange the removed parts in the correct order.
63. REMOVE EXHAUST VALVE
a. Using SST and wooden blocks, compress the compression spring and remove the valve retainer locks.
SST 09202-70020 (09202-00010)
b. Remove the retainer, compression spring and valve.
HINT: Arrange the removed parts in the correct order.
64. REMOVE VALVE STEM OIL SEAL
a. Using needle-nose pliers, remove the oil seals.
65. REMOVE VALVE SPRING SEAT
a. Using compressed air and a magnetic finger, remove the valve spring seat by blowing air onto it.
66. REMOVE NO.1 WITH HEAD STRAIGHT SCREW PLUG
a. Using a 10 mm hexagon wrench, remove the 4 screw plugs and 4 gaskets.
NOTICE: If water leaks from the with head straight screw plug No.1 or the plug corrodes, replace it.
67. REMOVE NO.2 WITH HEAD STRAIGHT SCREW PLUG
a. Using a 14 mm hexagon wrench, remove the screw plug and gasket.
NOTICE: If water leaks from the with head straight screw plug No.2 or the plug corrodes, replace it.
68. REMOVE UNION
a. Remove the union from the cylinder head.
69. REMOVE RING PIN
NOTICE: It is not necessary to remove ring pin unless it is being replaced.
70. REMOVE STUD BOLT
NOTICE: If the stud bolt is deformed or the threads are damaged, replace it.
71. REMOVE PISTON SUB-ASSEMBLY WITH CONNECTING ROD
a. Using a ridge reamer, remove all the carbon from the top of the cylinder.
b. Push the piston, connecting rod assembly and upper bearing through the top of the cylinder block.
HINT: Keep the bearing, connecting rod and cap together. Arrange the piston and connecting rod assemblies in the correct order.
72. REMOVE CONNECTING ROD BEARING
NOTICE: Arrange the removed parts in the correct order.
73. REMOVE CRANKSHAFT
a. Uniformly loosen and remove the 8 main bearing cap bolts and seal washers in the several steps and in the sequence shown in the illustration.
b. Uniformly loosen the 16 bearing cap bolts, in several steps, in the sequence shown in the illustration.
c. Using a screwdriver, pry out main bearing caps. Remove the 4 main bearing caps and lower bearings.
NOTICE:
^ Pull up the main bearing cap little by little to the right and the left by turns.
^ Be careful not to damage the joint surface of the cylinder block and the main bearing cap.
74. REMOVE CRANKSHAFT BEARING
HINT: Arrange the removed parts in the correct order.
75. REMOVE CRANKSHAFT THRUST WASHER SET
a. Remove the upper bearings and upper thrust washers from the cylinder block.
76. REMOVE PISTON RING SET
a. Using a piston ring expander, remove the 2 compression rings.
b. Using a piston ring expander, remove the oil ring rail.
c. Remove the oil ring expander by hand.
HINT: Arrange the removed parts in the correct order.
77. REMOVE WITH PIN PISTON SUB-ASSEMBLY
a. Check the fitting condition 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.
b. 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 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:
^ The piston and pin are a matched set.
^ Arrange the pistons, pins, rings, connecting rods and bearings in the correct order.
c. Using a gasket scraper, remove the carbon from the piston top.
d. Using a groove cleaning tool or broken ring, clean the piston ring grooves.
e. Using solvent and a brush, thoroughly clean the piston.
NOTICE: Do not use a wire brush.
78. REMOVE NO.1 SUB-ASSEMBLY OIL NOZZLE
a. Using a 5 mm hexagon wrench, remove the oil nozzles.
b. Check the 3 oil nozzles for damage or clogging.